Process for coating substrates with aperture(s)

Abstract

A coating method for a component with at least one aperture includes providing a component having at least one aperture formed in a surface thereof; additively manufacturing a hollow member on a portion of the surface to define a space above each aperture, the portion of the surface being adjacent to the aperture, the hollow member having an inner peripheral geometry complementary to a peripheral geometry at least one of aperture; applying at least one coating over the surface of the component and around hollow member to form an applied coating having an applied coating thickness; and removing at least a portion of the hollow member to make a top portion of the hollow member coplanar with the applied coating to expose the space through the applied coating; wherein a lower portion of the hollow member remains to define the space through the applied coating.

What is claimed is: 
     
         1 . A coated component, the component comprising:
 a surface;   at least one aperture formed in the surface;   a coating layer on the surface, the coating layer including:
 at least one hollow member on the surface extending from the surface to an outer surface of the coating layer, each hollow member defining a space above a respective one of the at least one aperture, a perimeter of each hollow member being coincident with a perimeter of a respective one of the at least one aperture and having an inner peripheral geometry complementary to an inner peripheral geometry of the respective one of the at least one aperture; 
 a coating material on the surface and around the at least one hollow member, the coating material having a top surface coplanar with a portion of the at least one hollow member. 
   
     
     
         2 . The coated component of  claim 1 , wherein the coating material includes at least one of a thermal barrier coating composition, an environmental barrier coating composition, or a bond coat composition. 
     
     
         3 . The coated component of  claim 1 , wherein the at least one hollow member includes at least one of a thermal barrier coating composition, an environmental barrier coating composition, or a bond coat composition. 
     
     
         4 . The coated component of  claim 1 , wherein the at least one hollow member is formed with the respective one of the at least one aperture. 
     
     
         5 . The coated component of  claim 1 , wherein the at least one hollow member is formed by additively manufacturing the at least one hollow member on the surface and extending from the surface to an outer surface of the at least one hollow member. 
     
     
         6 . The coated component of  claim 1 , wherein the at least one hollow member includes an inner periphery aligned with an outer perimeter of the respective one of the at least one aperture. 
     
     
         7 . The coated component of  claim 1 , wherein the at least one aperture defines an axis disposed at a non-perpendicular angle to the surface, and a respective at least one hollow member is coaxial with an axis of the at least one aperture. 
     
     
         8 . The coated component of  claim 1 , wherein the component is a turbomachine component. 
     
     
         9 . The coated component of  claim 1 , wherein the at least one hollow member includes a ceramic material selected from a group including at least one of aluminum-oxide, zirconium-oxide, hafnium-oxide, yttria-stabilized zirconium-oxide, metallic material, silicon based material, graphite, aluminum oxide, yttria-stabilized zirconia. 
     
     
         10 . The coated component of  claim 1 , wherein the coating material includes a ceramic material selected from a group including at least one of aluminum-oxide, zirconium-oxide, hafnium-oxide, yttria-stabilized zirconium-oxide, metallic material, silicon based materials, graphite, aluminum oxide, or yttria-stabilized zirconia. 
     
     
         11 . The coated component of  claim 1 , wherein an inner periphery of the at least one hollow member aligns with an outer perimeter of the at least one aperture to define a coplanar transitional surface. 
     
     
         12 . The coated component of  claim 1 , wherein the coating material is applied by spraying the coating material with a spray gun disposed at an angle to the at least one aperture.