A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

A method and apparatus for consolidating granular feedstock material into a coating or bulk article is described. Typically, metal powder, either a pure metal or an alloy, is used as feedstock. However, mixtures of different metal powders may be used or mixtures of metal powders, metallic composite powders, and/or ceramic powders may be used as well. Feedstock material is injected into a rotating throwing wheel. The throwing wheel imparts kinetic energy to the feedstock material, accelerating individual feedstock particles to high velocities. The granular feedstock material is ejected from the throwing wheel by centrifugal forces at high velocities. When the particles impact a suitable surface with sufficient velocity, the feedstock powders will deposit and bond to the surface rather than rebounding or merely embedding, producing a deposition. By relative translation between the surface and the wheel, a coating or article is fabricated.

A method and apparatus for consolidating granular feedstock material into a coating or bulk article is described. Typically, metal powder, either a pure metal or an alloy, is used as feedstock. However, mixtures of different metal powders may be used or mixtures of metal powders, metallic composite powders, and/or ceramic powders may be used as well. Feedstock material is injected into a rotating throwing wheel. The throwing wheel imparts kinetic energy to the feedstock material, accelerating individual feedstock particles to high velocities. The granular feedstock material is ejected from the throwing wheel by centrifugal forces at high velocities. When the particles impact a suitable surface with sufficient velocity, the feedstock powders will deposit and bond to the surface rather than rebounding or merely embedding, producing a deposition. By relative translation between the surface and the wheel, a coating or article is fabricated.