Provided herein is heat resistant steel for a turbine housing of an automotive turbocharger. In some instances, the high heat resistant steel with low nickel has high tensile strength and high heat resistance at a high temperature. The low Ni content provides cost reduction.

The present invention provides high heat resistant steel with low Ni, in which a value of X/Y is 0.44 to 0.47, wherein the X is a value calculated by Equation 1, [Equation 1 is X=wt % of Cr+wt % of 1.5Si+wt % of 0.5Nb], and the Y is a value calculated by Equation 2 [Equation 2 is Y=wt % of Ni+wt % of 0.5Mn+wt % of 30C+wt % of 30N].

A gas turbine component for use in a gas turbine engine includes a substrate a ceramic-based thermal barrier coating (TBC), and a diffusion chromide bond coat between the base material and the TBC. A thermally grown oxide (TGO) layer can be formed on the bond coat prior to application of the TBC. The TBC and the TGO include a common metal oxide. The oxide can be sacrificially in use and soluble in a molten sulfate salt, make the coating system particularly suitable for use in a marine environment.

An oxide and non-oxide based ceramic matrix composite (CMC) component for a combustion turbine engine has a solidified ceramic core with a three-dimensional preform of ceramic fibers, embedded therein. Engineered surface features (ESFs) are cut into an outer surface of the core and fibers of the preform. A thermal barrier coat (TBC) is applied over and coupled to the core outer surface and the ESFs. The ESFs provide increased surface area and mechanically interlock the TBC, improving adhesion between the ceramic core and the TBC.

By the use of highly pure zirconium oxide material for the outermost thermal barrier coating of a two-layer thermal barrier coating system, improved and durable layer systems for high-temperature temperature use is provided. A ceramic thermal barrier layer system, comprising: a substrate, a metallic adhesion-promoting layer on the substrate, an inner ceramic layer on the adhesion-promoting layer, and an outer ceramic layer on the inner ceramic layer, wherein the inner ceramic layer and the outer ceramic layer together represent the ceramic thermal barrier layer on the adhesion-promoting layer, wherein the outer ceramic layer is at least 20% purer, than the inner ceramic layer in terms of its chemical composition.

A method for joining engine components includes positioning a first plurality of thermal protection structures across a thermal protection space between a first thermal protection surface and a second thermal protection surface. The first and second engine components are locally joined by forming a first plurality of transient liquid phase (TLP) or partial transient liquid phase (PTLP) bonds along corresponding ones of the first plurality of thermal protection structures between the first thermal protection surface and the second thermal protection surface. The second thermal protection surface is formed from a second surface material different from a first surface material of the first thermal protection surface.

A turbine abradable component includes a support surface and a thermally sprayed ceramic/metallic abradable substrate coupled to the support surface for orientation proximal a rotating turbine blade tip circumferential swept path. An elongated pixelated major planform pattern (PMPP) of a plurality of discontinuous micro surface features (MSF) project from the substrate surface. The PMPP repeats radially along the swept path in the blade tip rotational direction, for selectively directing airflow between the blade tip and the substrate surface. Each MSF is defined by a pair of first opposed lateral walls defining a width, length and height that occupy a volume envelope of 1-12 cubic millimeters. The PMPP arrays of MSFs provide airflow control of hot gasses in the gap between the abradable surface and the blade tip with smaller potential rubbing surface area than solid projecting ribs with similar planform profiles.

A system for coating a component is provided. The system includes a feedstock supply, a carrier fluid supply, and a thermal spray gun coupled in flow communication with the feedstock supply and the carrier fluid supply. The feedstock supply contains a substantially homogeneous powder mixture of a first powder and a second powder. The second powder is softer than the first powder and has a percentage by mass of the powder mixture of between about 0.1% and about 3.0%.

An article (50; 100) has a metallic substrate (22), a bondcoat (30) atop the substrate, and a thermal barrier coating (28; 27, 28) atop the bondcoat. The thermal barrier coating or a layer thereof comprises didymium oxide and zirconia.

A method for joining engine components includes positioning a first plurality of thermal protection structures across a thermal protection space between a first thermal protection surface and a second thermal protection surface. The first and second engine components are locally joined by forming a first plurality of transient liquid phase (TLP) or partial transient liquid phase (PTLP) bonds along corresponding ones of the first plurality of thermal protection structures between the first thermal protection surface and the second thermal protection surface. The second thermal protection surface is formed from a second surface material different from a first surface material of the first thermal protection surface.

Cooling holes in a turbine component, such as a blade, vane or combustor transition, are formed in and surrounded by a micro surface feature (MSF) that protects the adjoining thermal barrier coating (TBC) from delamination or crack propagation during the hole formation or during engine operation. The MSF effectively functions as a circumferential sleeve around the cooling hole margin so that relatively more friable TBC material that would otherwise define the cooling hole margin is not directly exposed to coolant fluid exhausting the hole, foreign object damage (FOD) or contact with cooling hole formation tooling when fabricating the hole through the TBC layer. The MSF is formed as a projection from the component substrate or during subsequent application of a metallic bond coat (BC) layer.