A gas turbine engine article includes a silicon-containing ceramic substrate and an environmental barrier coating (EBC) system disposed on the substrate. The EBC system includes, from the substrate, a dense bond coat layer, a porous bond coat layer, and a topcoat layer in contact with the porous bond coat layer. The dense bond coat layer and the porous bond coat layer each include a silica matrix and oxygen-scavenging gas-evolution particles dispersed through the silica matrix. The porous bond coat layer includes engineered pores.

A gas turbine engine article includes a silicon-containing ceramic substrate and an environmental barrier coating (EBC) system disposed on the substrate. The EBC system includes, from the substrate, a dense bond coat layer, a porous bond coat layer, and a topcoat layer in contact with the porous bond coat layer. The dense bond coat layer and the porous bond coat layer each include a silica matrix and oxygen-scavenging gas-evolution particles dispersed through the silica matrix. The porous bond coat layer includes engineered pores.

A method of applying a protective coating to a substrate includes the steps of: providing a turbine engine component substrate formed of a ceramic matrix composite material, forming an environmental barrier coating layer including a rare earth disilicate material directly on the substrate, treating an outer surface of the environmental barrier coating layer to form a thermal barrier coating layer including a porous rare earth monociliate material directly on the environmental barrier coating layer. The step of treating the outer surface is performed using a thermal process consisting of the application of heat or a chemical-thermal process consisting of the application of heat and a chemical. The method further includes infiltrating at least a portion of the pores with a metal solution or suspension.

A method of applying a protective coating to a substrate includes the steps of: providing a turbine engine component substrate formed of a ceramic matrix composite material, forming an environmental barrier coating layer including a rare earth disilicate material directly on the substrate, treating an outer surface of the environmental barrier coating layer to form a thermal barrier coating layer including a porous rare earth monociliate material directly on the environmental barrier coating layer. The step of treating the outer surface is performed using a thermal process consisting of the application of heat or a chemical-thermal process consisting of the application of heat and a chemical. The method further includes infiltrating at least a portion of the pores with a metal solution or suspension.

A protective coating system includes a turbine engine component substrate formed of a ceramic matrix composite material, an environmental barrier coating layer including a rare earth disilicate material formed directly on the substrate, and a thermal barrier coating layer including a porous rare earth monosilicate material having a metal silicate material infiltrated within at least a portion of the pores formed directly on the environmental barrier coating layer.

A protective coating system includes a turbine engine component substrate formed of a ceramic matrix composite material, an environmental barrier coating layer including a rare earth disilicate material formed directly on the substrate, and a thermal barrier coating layer including a porous rare earth monosilicate material having a metal silicate material infiltrated within at least a portion of the pores formed directly on the environmental barrier coating layer.

A turbine engine part coated in at least a first ceramic layer forming a thermal barrier and including a ceramic material with first ceramic fibers dispersed in the first layer. The first layer may have a chemical composition gradient between a material for forming a thermal barrier and a material for providing protection against calcium and magnesium aluminosilicates, which is present at a greater content in an outer zone of the first layer, and/or the first layer may be porous and may present a porosity gradient such that an outer portion of the first layer presents lower porosity.

A turbine engine part coated in at least a first ceramic layer forming a thermal barrier and including a ceramic material with first ceramic fibers dispersed in the first layer. The first layer may have a chemical composition gradient between a material for forming a thermal barrier and a material for providing protection against calcium and magnesium aluminosilicates, which is present at a greater content in an outer zone of the first layer, and/or the first layer may be porous and may present a porosity gradient such that an outer portion of the first layer presents lower porosity.

Methods for fabricating protective coating systems for gas turbine engine applications are provided. An exemplary method of applying a protective coating to a substrate includes the steps of providing a substrate formed of a ceramic matrix composite material, forming a first coating layer directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and forming a second coating layer directly on to the first coating layer and comprising a thermal barrier material. The method optionally includes forming a third coating layer partially directly on to the second coating layer and partially within at least some of the plurality of pores of the second coating layer.

Methods for fabricating protective coating systems for gas turbine engine applications are provided. An exemplary method of applying a protective coating to a substrate includes the steps of providing a substrate formed of a ceramic matrix composite material, forming a first coating layer directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and forming a second coating layer directly on to the first coating layer and comprising a thermal barrier material. The method optionally includes forming a third coating layer partially directly on to the second coating layer and partially within at least some of the plurality of pores of the second coating layer.