Article having composite layer

Abstract

A composite article includes a substrate and a layer attached to the substrate. The layer includes a metal phase, a first ceramic phase, and a second ceramic phase.

1 . A method of manufacturing a composite article, comprising:
 forming the composite article with a layer having a metal phase, a first ceramic phase, and a second ceramic phase.   
     
     
         2 . The method as recited in  claim 1 , comprising melting the second ceramic phase, and coating a solid surface of the first ceramic phase with the melted second ceramic phase. 
     
     
         3 . The method as recited in  claim 1 , comprising thermal spraying a first powder comprising the metal phase and a second powder comprising the first ceramic phase and the second ceramic phase. 
     
     
         4 . The method as recited in  claim 1 , comprising forming the second powder with about 1-33 wt % of the second ceramic phase and a remainder being the first ceramic phase. 
     
     
         5 . The method as recited in  claim 1 , comprising forming the second powder with about 10-20 wt % of the second ceramic phase and a remainder being the first ceramic phase. 
     
     
         6 . The method as recited in  claim 1 , comprising forming the second powder with about 10 wt % of the second ceramic phase and a remainder being the first ceramic phase. 
     
     
         7 . The method as recited in  claim 1 , wherein the second powder comprises a polymer.