A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.

The present disclosure provides a composite coating and a method for fabricating the composite coating. The composite coating comprises a polymer layer, a metal interlayer and an amorphous metal coating. The polymer layer is formed on a substrate and acts as a diffusion barrier layer, which is thick and dense enough to prevent the corrosive substances from penetrating into the substrate. The metal interlayer is formed between the polymer layer and the amorphous metal coating for improving the adhesion of the amorphous metal coating to the substrate.

A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.

Disclosed is a method for manufacturing free-standing cladding tubes with multi-layer structures. According to the method, a cylindrical mandrel substrate defining a hollow cylindrical inner space is provided. A first cold spray powder metal is selected. The cylindrical mandrel substrate is rotated and the first cold spray powder metal is applied to an outer surface of the cylindrical mandrel substrate to form a first layer. The cylindrical mandrel substrate is removed.

A method of applying a long lasting wear-resistant coating on a Yankee drying cylinder is described, whereby the method includes: providing a Yankee drying cylinder having a cylindrical shell with a circular cross-section and an outer surface; and performing a thermal spray operation to form a wear-resistant coating layer on the outer surface of the Yankee drying cylinder during which thermal spray operation coating feedstock is fed to at least one spray device, heated to become plastic and/or semi-molten and/or molten and sprayed onto the outer surface of the Yankee drying cylinder to form the wear-resistant coating layer. The coating feedstock for the thermal spray operation consists of a specific set of elements, by percent weight, with the remainder being iron and impurities. Coatings and Yankee cylinders with such coatings are also disclosed.

A method of applying a long lasting wear-resistant coating on a Yankee drying cylinder (1), the method comprises: the step of providing a Yankee drying cylinder (1) having a cylindrical shell (2) with a circular cross-section and an outer surface (3); the step of performing a thermal spray operation to form a wear-resistant coating layer (4) on the outer surface of the Yankee drying cylinder (1) during which thermal spray operation coating feedstock (6) is fed to at least one spray device (5), heated to become plastic and/or semi-molten and/or molten and sprayed onto the outer surface (3) of the Yankee drying cylinder (1) to form the wear-resistant coating layer (4), the coating feedstock (6) for the thermal spray operation consisting of: 1.5 to 2.5 weight percent Al 0.0 to 0.2 weight percent Ti, 9.5 to 10.5 weight percent Si, 0.0 to 0.2 weight percent B, 12.5 to 14.2 weight percent Mo, 0.0 to 0.2 weight percent V, 0.0 to 0.2 weight percent C, 0.000 to 0.020 weight percent Cr, 4.5 to 6.0 weight percent Mn, 0.0 to 0.2 weight percent Mg, 0.0 to 0.2 weight percent Ni, 0.0 to 0.2 weight percent Nb, the remainder being iron and impurities.

Coatings and Yankee cylinders with such coatings are also disclosed.

A thin-walled metal part, and a method to fabricate such a part out of various alloys. A plurality of layers are formed, each of the layers being formed on a polymer template or on a previously formed layer. A homogenizing heat treatment is used to cause chemical elements in the layers to interdiffuse, to form a single continuous layer with a substantially uniform alloy composition.

The present invention provides a thermal barrier coated component, monitoring or evaluation of the soundness of which is able to be adequately carried out on the basis of the thermal boundary conditions that are detected by a sensor. A thermal barrier coated component according to the present invention comprises: a base material; a first bond coat layer that is a metal bonding layer formed on the base material; a sensor unit that comprises a sensor and a conductive wire, which are formed on the first bond coat layer; a second bond coat layer that is formed on the first bond coat layer so as to cover at least the sensor unit, while having a surface roughness higher than that of the first bond coat layer; and a top coat layer that is formed on the second bond coat layer.

A coating system for a surface of a superalloy component is provided. The coating system includes a MCrAlY coating on the surface of the superalloy component, where M is Ni, Fe, Co, or a combination thereof. The MCrAlY coating generally has a higher chromium content than the superalloy component. The MCrAlY coating also includes a platinum-group metal aluminide diffusion layer. The MCrAlY coating includes Re, Ta, or a mixture thereof. Methods are also provided for forming a coating system on a surface of a superalloy component.

A component of a gas turbine engine comprises a substrate, a corrosion resistant top layer, and an intermediate corrodible layer disposed between the corrosion resistant top layer and the substrate. When corroding, the intermediate layer has a color contrasting with a color of the top layer. A method of detecting a crack when it penetrated the top layer in a component of a gas turbine engine having a corrosion resistant top layer and an intermediate corrodible layer comprises, in sequence, observing that at least one area of the component has a color contrasting with that of the top layer; determining that the color of the at least one area is a result of corrosion of the intermediate corrodible layer; and determining that the top layer has a crack as a result of determining corrosion of the intermediate layer. A method of facilitating crack detection in a component is also presented.