Method for creating a textured bond coat surface

Abstract

A method for creating a textured surface ( 52 ) of bond coat material ( 18 ) for improving the performance of a thermal barrier coating system ( 12 ). A plurality of columns ( 62 ) of bond coat material are formed by spraying ( 52 ) the material through a corresponding plurality of openings ( 32 ) in a mask ( 30 ) applied to a surface ( 40 ) to be textured. The openings may be formed in only a region ( 34 ) of the mask in response to an image of the surface to be textured. The mask and excess material ( 54 ) applied over the mask are then removed to reveal the textured surface.

1 . A method comprising:
 removing a portion of an existing thermal barrier coating from a gas turbine engine component to reveal a region of a surface to be coated;   forming a mask comprising a plurality of openings formed therethrough corresponding to a desired pattern of surface features to be created in a replacement bond coat layer;   applying the mask to the region of the surface to be coated;   depositing bond coat material over the mask and onto a base layer of the bond coat material disposed on the surface through the openings in the mask; and   removing the mask and excess bond coat material deposited over the mask to reveal the replacement bond coat layer having the desired pattern of surface features disposed on the base layer of the bond coat material.   
     
     
         2 . The method of  claim 1 , further comprising:
 removing all layers of the portion of the existing thermal barrier coating to reveal a region of a superalloy material surface of the component; and   applying the base layer of the bond coat material onto the superalloy material surface prior to applying the mask.   
     
     
         3 . The method of  claim 1 , further comprising:
 forming the mask of a polymer material;   removing the excess bond coat material using a mechanical process; and   removing the mask using a heating step.   
     
     
         4 . The method of  claim 1 , further comprising:
 obtaining an image of the region of the surface to be coated;   using the image to form the mask to comprise openings only in a region of the mask corresponding to the region of the surface to be coated.   
     
     
         5 . The method of  claim 1 , further comprising varying at least one of a cross-sectional shape of the openings or a spacing between openings across the mask. 
     
     
         6 . A method comprising:
 forming a mask comprising a plurality of holes corresponding to a desired pattern of surface features of a bond coat of a thermal barrier coating system;   applying the mask to a surface to be coated;   directing a spray of bond coat material over the mask and onto the surface through the holes in the mask;   removing bond coat material deposited onto the mask; and   removing the mask to reveal the desired pattern of surface features in the bond coat material deposited onto the surface.   
     
     
         7 . The method of  claim 6 , further comprising forming the plurality of holes in the mask in response to an image of the surface to be coated. 
     
     
         8 . The method of  claim 6 , further comprising varying a size, shape or spacing of the holes across the mask. 
     
     
         9 . A method comprising:
 forming a mask comprising a plurality of openings;   applying the mask to a surface of a gas turbine engine component;   directing a spray of an alloy material through the openings of the mask and onto the surface;   removing the mask and any excess alloy material deposited onto the mask to reveal a pattern of the alloy material on the surface; and   applying a ceramic material over the patterned alloy material.   
     
     
         10 . The method of  claim 9 , further comprising applying a ceramic insulating material over the patterned alloy material. 
     
     
         11 . The method of  claim 9 , further comprising applying an abradable ceramic material over the patterned alloy material. 
     
     
         12 . The method of  claim 9 , further comprising forming the plurality of holes in the mask in response to an image of the surface to be coated. 
     
     
         13 . The method of  claim 9 , wherein the gas turbine engine component comprises a base layer of bond coat material that defines the surface onto which the spray of alloy material is directed.