The present disclosure provides for improvements in fixturing parts in preparation for an electroplating process, thus reducing part handling. The system provides a reusable masking tool comprising a main body having an opening with a removeable coverplate positioned within the opening and one or more locking tabs engaging a corresponding relief slot in at least one of the sidewalls of the main body. The system also comprises a fastener moveably secured within the main body and extending through a top surface of the main body. The main body, fastener, and coverplate may be fabricated from a polymer material by way of an additive manufacturing process. A shank, fabricated from a conductive material, extends through the fastener and is engaged with the fastener such that upon rotation of the fastener, the shank is drawn into contact with the gas turbine engine component, thus providing a conduit for the electroplating process.

A gas turbine engine component made of a nickel-based superalloy, the gas turbine engine component comprising a protective coating. The protective coating includes an inner diffusion barrier layer including any one or any combination of elements selected from the group consisting of platinum, palladium, tantalum, tungsten, hafnium and iridium, and an outer layer of hard material formed of hard particles embedded in a matrix.

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 method of using a masking device to mask a portion of a gas turbine engine component for an electroplating process is provided. The masking device includes a main body having sidewalls, a removeable coverplate having an end plate and one or more locking tabs, a fastener located at least partially within the main body, and a shank engaged with the fastener. The method includes placing the gas turbine engine component through an opening in the main body such that the component is held within the main body by a retention slot. The method includes sliding the one or more locking tabs of the removeable coverplate through the opening in the main body such that the removeable coverplate covers the opening of the main body. The method includes securing the one or more locking tabs in one or more relief slots in the sidewalls of the main body.

A method for forming a coating on a surface of an airfoil is provided, where the airfoil has a leading edge, a trailing edge, a pressure side, and a suction side. The method can include forming a platinum-group metal layer on the surface of the airfoil along at least a portion of the trailing edge, and forming an aluminide coating over the surface of the airfoil of the leading edge, the trailing edge, the pressure side, and the suction side. The leading edge may be substantially free from any platinum-group metal. The method may further include, prior to forming the aluminide coating, forming a bond coating on the surface of the airfoil along the leading edge, and after forming the aluminide coating, forming a thermal barrier coating over the bond coating. A method is also generally provided for repairing a coating on a surface of an airfoil.

A composite thermal barrier coating (TBC) may be applied to a surface of components within an internal combustion engine. The composite TBC provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The composite TBC includes three layers, bonded to one another, i.e., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component and to the insulating layer. The insulating layer includes hollow microspheres that are sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer is a thin film that is configured to resist the high temperatures, present within the engine. The sealing layer is impermeable to gasses and presents a smooth surface.

A piston capable of reducing undesirable “knock,” reducing hydrocarbon emissions, and providing more complete combustion, is provided. The piston includes a multilayer coating having a thickness of 500 microns or less disposed on an upper combustion surface. The coating includes a bond layer including nickel disposed on the upper combustion surface. A thermal barrier layer including a ceramic composition is disposed on the bond layer. A sealant layer formed of metal is disposed on the thermal barrier layer. A catalytic layer including at least one of platinum, ruthenium, rhodium, palladium, osmium, and iridium is disposed on the sealant layer. The catalytic layer can be disposed on select regions or the entire upper combustion surface to promote combustion through a catalyzed reaction.

An article includes a substrate formed of a molybdenum-based alloy. The molybdenum-based alloy has a composition that includes molybdenum, silicon, and boron. A barrier layer is disposed on the substrate. The barrier layer is formed of at least one noble metal.

An article includes a substrate formed of a molybdenum-based alloy. A barrier layer is disposed on the substrate. The barrier layer is formed of at least one noble metal.

The present disclosure provides for improvements in fixturing parts in preparation for an electroplating process, thus reducing part handling. The system provides a reusable masking tool comprising a main body having an opening with a removeable coverplate positioned within the opening and one or more locking tabs engaging a corresponding relief slot in at least one of the sidewalls of the main body. The system also comprises a fastener moveably secured within the main body and extending through a top surface of the main body. The main body, fastener, and coverplate may be fabricated from a polymer material by way of an additive manufacturing process. A shank, fabricated from a conductive material, extends through the fastener and is engaged with the fastener such that upon rotation of the fastener, the shank is drawn into contact with the gas turbine engine component, thus providing a conduit for the electroplating process.