A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate. A preform meter section and a preform diffuser section are formed in the substrate. An internal coating is applied to at least the preform meter section to provide a meter section of a cooling aperture. External coating material is applied over the substrate. The applying of the external coating material forms an external coating over the substrate. The applying of the external coating also builds up the external coating material within the preform diffuser section to form a diffuser section of the cooling aperture.

A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

A composite substrate includes, in this order: a ceramic plate; a metal layer containing at least one selected from the group consisting of aluminum and an aluminum alloy; and a thermal sprayed layer containing at least one selected from the group consisting of copper and a copper alloy, and an intermetallic compound containing copper and aluminum as constituent elements is scattered between the metal layer and the thermal sprayed layer.

A composite substrate includes, in this order: a ceramic plate; a metal layer containing at least one selected from the group consisting of aluminum and an aluminum alloy; and a thermal sprayed layer containing at least one selected from the group consisting of copper and a copper alloy, and an intermetallic compound containing copper and aluminum as constituent elements is scattered between the metal layer and the thermal sprayed layer.

A hearth roll for a continuous annealing furnace, the hearth roll comprising a thermal spray coating on a surface of the hearth roll, wherein the thermal spray coating comprises main components consisting of a Co-based alloy, a carbide of a transition metal, and a double oxide; and impurities, the double oxide consists of one or two types of a first double oxide consisting of Al and a rare earth element and a second double oxide consisting of a transition metal and a rare earth element, and when the main components are 100 mass %, a content of the Co-based alloy is 25 mass % or more and 50 mass % or less, a content of the carbide is 5 mass % or more and 30 mass % or less, and a content of the double oxide is 20 mass % or more and 45 mass % or less.

A hearth roll for a continuous annealing furnace, the hearth roll comprising a thermal spray coating on a surface of the hearth roll, wherein the thermal spray coating comprises main components consisting of a Co-based alloy, a carbide of a transition metal, and a double oxide; and impurities, the double oxide consists of one or two types of a first double oxide consisting of Al and a rare earth element and a second double oxide consisting of a transition metal and a rare earth element, and when the main components are 100 mass %, a content of the Co-based alloy is 25 mass % or more and 50 mass % or less, a content of the carbide is 5 mass % or more and 30 mass % or less, and a content of the double oxide is 20 mass % or more and 45 mass % or less.

A method of assessing the quality of a bond coat for bonding a ceramic coating to a metallic substrate comprises determining a thresholded summit area for the bond coat.

A method of assessing the quality of a bond coat for bonding a ceramic coating to a metallic substrate comprises determining a thresholded summit area for the bond coat.

A method for predetermining a thickness of a coating which is to be arranged on a substrate is provided. A spray spot is arranged on a surface of the substrate or a test substrate. The volume of the spray spot is determined, and based on the determined volume, the thickness of a layer which is to be applied is worked out. An arrangement for predetermining the thickness of a coating is further provided.