Process for coating articles and articles made therefrom

Abstract

In one embodiment, a coated turbine article comprising a uniform enhanced coating on at least a portion of the turbine article, wherein the enhanced coating comprises a coating material and a structural enhancer, wherein the structural enhancer is selected from the group consisting of oxide, carbide, nitride, intermetallic material, and combinations comprising at least one of the foregoing, wherein the structural enhancer has an average particle size, as measured along a major axis, of about 0.01 μm to about 100 μm.

1 . A method of forming a coated article, comprising: 
 forming a mixture of a coating material and a structural enhancer selected from the group consisting of oxide, carbide, nitride, intermetallic material, and combinations comprising at least one of the foregoing, wherein the mixture comprises an initial structural enhancer concentration;    heating the mixture; and    propelling the mixture at the article to form an enhanced coating, wherein the enhanced coating has a final structural enhancer concentration that is less than or equal to 5 vol % greater than the initial structural enhancer concentration, based upon a total volume of the enhanced coating.    
     
     
         2 . The method of  claim 1 , further comprising controlling a particle size of the structural enhancer.  
     
     
         3 . The method of  claim 1 , further comprising controlling a distribution of the structural enhancer in the coating.  
     
     
         4 . The method of  claim 1 , wherein the mixture comprises at least two of the structural enhancers.  
     
     
         5 . The method of  claim 1 , wherein the structural enhancer has an average particle size, as measured along a major axis, of about 0.01 μm to about 100 μm.  
     
     
         6 . The method of  claim 5 , wherein the average particle size is about 1 μm to about 50 μm.  
     
     
         7 . The method of  claim 6 , wherein the average particle size is about 5 μm to about 25 μm.  
     
     
         8 . The method of  claim 1 , wherein the structural enhancer comprises intermetallic material.  
     
     
         9 . The method of  claim 1 , wherein the structural enhancer comprises an oxide.  
     
     
         10 . The method of  claim 9 , wherein the structural enhancer comprises aluminum oxide.  
     
     
         11 . The method of  claim 1 , wherein the structural enhancer comprises a nitride.  
     
     
         12 . The method of  claim 1 , wherein the enhanced coating comprises MCrAlY, wherein M is selected from the group consisting of nickel, cobalt, iron, and combinations comprising at least one of the foregoing.  
     
     
         13 . The method of  claim 12 , wherein the enhanced coating further comprises an element selected from the group consisting of silicon, ruthenium, iridium, osmium, gold, silver, tantalum, palladium, rhenium, hafnium, platinum, rhodium, tungsten, alloys comprising at least one of the foregoing, and combinations comprising at least one of the foregoing.  
     
     
         14 . The article of  claim 13 , wherein the enhanced coating comprises an element selected from the group consisting of ruthenium, iridium, osmium, gold, silver, tantalum, palladium, rhenium, platinum, rhodium, tungsten, alloys comprising at least one of the foregoing, and combinations comprising at least one of the foregoing.  
     
     
         15 . The method of  claim 1 , wherein the final structural enhancer concentration is about 1 vol % to about 25 vol %, based upon a total volume of the enhanced coating.  
     
     
         16 . The article of  claim 15 , wherein the final structural enhancer concentration is of about 5 vol % to about 15 vol %.  
     
     
         17 . The article of  claim 1 , wherein the enhanced coating has a uniform concentration of the structural enhancer.  
     
     
         18 . A method of forming a coated article, comprising: 
 forming a mixture of a coating material and a structural enhancer, wherein the structural enhancer comprises an aluminum oxide, wherein the mixture comprises an initial structural enhancer concentration;    heating the mixture; and    propelling the mixture at the article to form an enhanced coating,    wherein the enhanced coating has a final structural enhancer concentration that is less than or equal to 5 vol % greater than the initial structural enhancer concentration, based upon a total volume of the enhanced coating; and    wherein the enhanced coating comprises MCrAlY, wherein M is selected from the group consisting of nickel, cobalt, iron, and combinations comprising at least one of the foregoing.