Patent ID: 7078073
Filing Date: 2006-07-18
Classification: C23C,F01D,F05D,Y10T

Abstract:
1. A method for repairing a coated component, which has been exposed to engine operation, to restore coated dimensions of the component and increase subsequent engine operation efficiency, comprising: a) providing an engine run component including a base metal substrate having thereon a thermal barrier coating system, the thermal barrier coating system comprising a bond coat on the base metal substrate and a top ceramic thermal barrier coating, the top ceramic thermal barrier coating having a nominal thickness t; wherein the component including the bond coat thereon before engine operation has a weight, w b) removing completely the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining thickness of the base metal substrate removed, the portion of the base metal substrate removed having a thickness, Δt; wherein the component has a weight, w c) reapplying the bond coat to the substrate at a thickness which is about the same as the thickness applied prior to the engine operation; wherein after application of the bond coat the component is weighed, denoted by w d) reapplying a top ceramic thermal barrier coating to a nominal thickness of t+Δt, wherein Δt compensates for the portion of base metal substrate removed in b) to restore adjacent airfoil to airfoil throat distance to about the distance preceding the engine run so that the dimensions of the coated component are restored to about the coated dimensions preceding the engine run to increase subsequent engine operation efficiency, wherein the thermal barrier coating of d) is applied at a thickness greater than the thermal barrier coating a); and weight of the component having the bond coat of c) and the thermal barrier coating of d) thereon is denoted by w