A coating system (1) is provided which includes an ultrasonic sprayer (3) capable of spraying a coating fluid onto a target surface (5). A convective or infrared heater (21) is associated with the sprayer and is operable to heat the spray (23) produced by the sprayer (3).

A method for masking cooling passages of a turbine component having an external surface, an internal cavity for receiving cooling air, and cooling passages extending therebetween. The location and angle of cooling passages are determined using a robotic arm and a location system. A masking device is placed in the cooling passages located during the locating step. The masking device includes a head portion having a gripping feature for gripping by a robotic arm, and a locating feature for orientation of the masking device by the robotic arm. A retaining portion extending from the head portion is arranged and disposed to retain the masking device in a cooling passage. The retaining portion is narrower proximate a distal end than proximate the head portion. The component and head portion of the masking devices are coated. The masking devices may be removed using the robotic arm and locating system.

A method for masking cooling passages of a turbine component having an external surface, an internal cavity for receiving cooling air, and cooling passages extending therebetween. The location and angle of cooling passages are determined using a robotic arm and a location system. A masking device is placed in the cooling passages located during the locating step. The masking device includes a head portion having a gripping feature for gripping by a robotic arm, and a locating feature for orientation of the masking device by the robotic arm. A retaining portion extending from the head portion is arranged and disposed to retain the masking device in a cooling passage. The retaining portion is narrower proximate a distal end than proximate the head portion. The component and head portion of the masking devices are coated. The masking devices may be removed using the robotic arm and locating system.

Cord having an equivalent outside diameter (d) of between 1 mm and 3.5 mm and consisting of a core (18) in the form of a wire, and a sheath (20) covering the core along its entire length, the core consisting of a collection of inorganic particles (22) of which the median size (D.sub.50) is less than 10 micrometers, the inorganic particles representing more than 40% and less than 80% of the volume of the core; and of a matrix (24) binding said inorganic particles, the matrix comprising a polymer binder and optionally a matrix lubricant, these together representing more than 90% of the volume of the matrix; the sheath having a thickness of between 50 micrometers and 500 micrometers and comprising a sheath polymer and preferably a sheath lubricant, these together representing more than 90% of the volume of the sheath, the volume percentages being determined without accounting for the possible presence of a solvent.

An alloy wheel is formed having a three dimensional configuration defining a face and recessed surfaces. The face of the wheel is machined providing a smooth surface at the face and defining an edge between the smooth surface of the face and the recessed surfaces. A nozzle element for projecting a plasma jet toward the wheel is provided. The plasma jet is projected toward the smooth surface of the face, the edge, and toward at least a portion of the recessed surfaces forming an alloy oxide at least on the face and the edge disposed between the face and the recessed surfaces. A first polymeric coating is applied over the face, the recessed surfaces and the edge disposed between the face and the recessed surfaces.