# Patent

## Title
Method for repairing coated components

## Abstract

According to an embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, is disclosed. The method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the base metal substrate removed. The portion of the base metal substrate removed has a thickness, Δt. The method also comprises reapplying the diffusion bond coat to the substrate, wherein the bond coat is reapplied to a thickness, which is about the same as applied prior to the engine operation; and reapplying the top ceramic thermal barrier coating to a nominal thickness of t+Δt, wherein Δt compensates for the portion of removed base metal substrate. Advantageously, the coated airfoil contour dimensions of the high pressure turbine blade are restored to about the coated dimensions preceding the engine run.

## Background
CROSS-REFERENCE TO RELATED APPLICATION
The subject application shares certain attributes with U.S. Serial Nos. entitled, Method for Repairing Coated Components Using NiAl Bond Coats and Method for Repairing Components Using Environmental Bond Coatings and Resultant Coatings, respectively, filed concurrently herewith.
FIELD OF THE INVENTION
The invention generally relates to a method for repairing coated components exposed to high temperatures during, for example, gas turbine engine operation. More particularly, the invention relates to a method for removing and refurbishing a thermal barrier coating system that includes an inner metallic bond coat and an outer thermal insulating ceramic layer.
BACKGROUND OF THE INVENTION
Higher operating temperatures for gas turbine engines are continuously sought in order to increase efficiency. However, as operating temperatures increase, the high temperature durability of the components within the engine must correspondingly increase.
Significant advances in high temperature capabilities have been achieved through the formulation of nickel- and cobalt-based superalloys. For example, some gas turbine engine components may be made of high strength directionally solidified or single crystal nickel-based superalloys. These components are cast with specific external features to do useful work with the core engine flow and contain internal cooling details and through-holes to provide external film cooling to reduce airfoil temperatures. Nonetheless, when exposed to the demanding conditions of gas turbine engine operation, particularly in the turbine section, such alloys alone may be susceptible to damage by oxidation and corrosion attack and may not retain adequate mechanical properties. Thus, these components often are protected by an environmental coating or bond coat and a top thermal insulating coating often collectively referred to as a thermal barrier coating (TBC) system.
Diffusion coatings, such as aluminides and platinum aluminides applied by chemical vapor deposition processes, and overlay coatings such as MCrAlY alloys, where M is iron, cobalt and/or nickel, have been employed as environmental coatings for gas turbine engine components.
Ceramic materials, such as zirconia (ZrO2) partially or fully stabilized by yttria (Y2O3), magnesia (MgO) or other oxides, are widely used as the topcoat of TBC systems. The ceramic layer is typically deposited by air plasma spraying (APS) or a physical vapor deposition (PVD) technique. TBC employed in the highest temperature regions of gas turbine engines is typically deposited by electron beam physical vapor deposition (EB-PVD) techniques.
To be effective, the TBC topcoat must have low thermal conductivity, strongly adhere to the article and remain adherent throughout many heating and cooling cycles. The latter requirement is particularly demanding due to the different coefficients of thermal expansion between thermal barrier coating materials and superalloys typically used to form turbine engine components. TBC topcoat materials capable of satisfying the above requirements have generally required a bond coat, such as one or both of the above-noted diffusion aluminide and MCrAlY coatings. The aluminum content of a bond coat formed from these materials provides for the slow growth of a strong adherent continuous alumina layer (alumina scale) at elevated temperatures. This thermally grown oxide protects the bond coat from oxidation and hot corrosion, and chemically bonds the ceramic layer to the bond coat.
Though significant advances have been made with coating materials and processes for producing both the environmentally-resistant bond coat and the thermal insulating ceramic layer, there is the inevitable requirement to remove and replace the environmental coating and ceramic top layer under certain circumstances. For instance, removal may be necessitated by erosion or impact damage to the ceramic layer during engine operation, or by a requirement to repair certain features such as the tip length of a turbine blade. During engine operation, the components may experience loss of critical dimension due to squealer tip loss, TBC spallation and oxidation/corrosion degradation. The high temperature operation also may lead to growth of the environmental coatings.
Current state-of-the art repair methods often result in removal of the entire TBC system, i.e., both the ceramic layer and bond coat. One such method is to use abrasives in procedures such as grit blasting, vapor honing and glass bead peening, each of which is a slow, labor-intensive process that erodes the ceramic layer and bond coat, as well as the substrate surface beneath the coating. The ceramic layer and metallic bond coat also may be removed by a stripping process in which, for example, the part is soaked in a solution containing KOH to remove the ceramic layer and also soaked in acidic solutions, such as phosphoric/nitric solutions, to remove the metallic bond coat. Although stripping is effective, this process also may remove a portion of the base substrate thereby thinning the exterior wall of the part.
When components such as high pressure turbine blades are removed for a full repair, the ceramic and diffusion coatings may be removed from the external locations by stripping processes. The tip may then be restored, if needed, by weld build up followed by other shaping processes. The diffusion coatings and ceramic layer are then reapplied to the blades in the same thickness as if applied to a new component. However, airfoil and environmental coating dimensions/stability are particularly important for efficient engine operation and the ability for multiple repairs of the components. When design is limited to particular minimum airfoil dimensions, multiple repairs of such components may not be possible.
BRIEF DESCRIPTION OF THE INVENTION
Applicants have determined that if conventional processes are used in the afore-described repair, the original or pre-repair coated airfoil section dimensions are not restored and thus blade-to-blade throat distances (distance between adjacent airfoil sections in an engine) increase. Applicants have further determined that such changes in airfoil dimension may substantially affect turbine efficiency.
Accordingly, there exists a need for a method of repairing a coated gas turbine engine component, which compensates for the base metal loss as a result of coating removal processes. There also is a need for a method of repairing a coated gas turbine engine component having an airfoil section, wherein the method compensates for the base metal loss as a result of coating removal processes and restores the airfoil section contour to its pre-repair or original coated airfoil contour dimensions. The present invention addresses these needs.
In one embodiment of the invention, 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, is disclosed. The method comprises providing an engine run component including a base metal substrate. The base metal substrate has thereon a 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 has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the removed base metal. The portion of the base metal substrate removed has a thickness, Δt. A bond coat is reapplied to the substrate at a thickness, which is about the same as the thickness applied prior to the engine operation. The method also comprises reapplying a top ceramic thermal barrier coating to a nominal thickness of t+Δt, where Δt compensates for the portion of removed base metal substrate. Advantageously, the dimensions of the coated component are restored to about the coated dimensions preceding the engine run to increase subsequent engine operation efficiency.
In another embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, is disclosed. This method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the removed base metal. The portion of the base metal substrate removed has a thickness, Δt. The method also comprises reapplying a diffusion bond coat to the substrate at a thickness, which is about the same as the thickness applied prior to the engine operation; and reapplying a top ceramic thermal barrier coating to a nominal thickness of t+Δt, wherein Δt compensates for the portion of removed base metal substrate. Advantageously, the coated airfoil contour dimensions of the blade are restored to about the dimensions preceding the engine run.
Applicants have determined how to provide further substrate and bond coat temperature reductions for airfoils, which increases ceramic spallation life, which lowers subsequent coating growth to be experienced in the next repair cycle, and which also provides further alloy mechanical property advantages. For example, this may be achieved through the addition of the herein described Δt TBC thickness.
Applicants also have determined how to compensate for base metal loss as a result of coating removal processes, and also restore airfoil section contour to its pre-repair or original coated airfoil contour dimensions, without a weight penalty. Thus, an important advantage of embodiments of the invention is that resulting airfoil throat area restoration will allow the turbine to run much more efficiently. For example, during conventional repair of an engine run component, about 3 mils of underlying base metal thickness may be removed in the process. Thus, about a 3 mil loss of base metal may be experienced on both the pressure and suction side of an airfoil, which translates into about a 6 mil increase in throat dimension (distance between adjacent airfoil sections in an engine). While this increase in gap between the components may not adversely affect the mechanical operation of the engine, Applicants have determined that operation efficiency may be substantially adversely affected. Embodiments of Applicants' invention present an innovative, much needed solution to the above problem, which is inexpensive to implement and does not require additional costly equipment.
Other features and advantages will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate by way of example the principles of the invention.



BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a high pressure turbine blade.
FIG. 2 is a local cross-sectional view of the blade of FIG. 1, along line 2—2 and shows a thermal barrier coating system on the blade.
FIG. 3 is a flow chart showing an embodiment of the process of the invention.



DETAILED DESCRIPTION OF THE INVENTION
The repair method of the present invention is generally applicable to components that operate within environments characterized by relatively high temperatures, and are therefore subjected to severe thermal stresses and thermal cycling. Notable examples of such components include the high and low pressure turbine nozzles and blades, shrouds, combustor liners and augmentor hardware of gas turbine engines. Other examples include airfoils, in general, and static parts such as vanes. One particular example is the high pressure turbine blade 10 shown in FIG. 1. For convenience, the method of the present invention will be described in the context of repairing blade 10. However, one skilled in the art will recognize that the method described below may be readily adapted to repairing any other gas turbine engine part coated with a thermal barrier coating system.
The blade 10 of FIG. 1 generally includes an airfoil 12 against which hot combustion gases are directed during operation of the gas turbine engine, and whose surface is therefore subject to severe attack by oxidation, corrosion and erosion. The airfoil 12 is anchored to a turbine disk (not show) with a dovetail 14 formed on a platform 16 of the blade 10. Cooling holes 18′ are present in the airfoil 12 through which bleed air is forced to transfer heat from the blade 10.
The base metal of the blade 10 may be any suitable material, including a superalloy of Ni or Co, or combinations of Ni and Co. Preferably, the base metal is a directionally solidified or single crystal Ni-base superalloy. For example, the base metal may be made of Rene N5 material having a density of about 8.64 g/cm3. The as cast thickness of the airfoil section 12 of blade 10 may vary based on design specifications and requirements.
The airfoil 12 and platform 16 may be coated with a thermal barrier coating system 18, shown in FIG. 2. The thermal barrier coating system may comprise a bond coat 20 disposed on the substrate of blade 10 and a ceramic thermal barrier coating 22 on top of the bond coat 20.
In an embodiment of the invention, the bond coat 20 is a diffusion coating and the base metal of the blade 10 is a directionally solidified or single crystal Ni-base superalloy. However, the base material also may include a combination of Ni and Co, as described above. Both the Ni in a nickel-base superalloy and Co in a cobalt-base superalloy diffuse outward from the substrate to form diffusion aluminides, and the superalloys may include both Ni and Co in varying percentages. While the discussion of the superalloy substrate may be in terms of Ni-base superalloys, it will be understood that a Co-base superalloy substrate may be employed. Similarly, the bond coat 20 may comprise a MCrAlY coating alone or in combination with a diffusion coating, as well as other suitable known coatings.
According to an embodiment of the invention, the diffusion coating may comprise simple or modified aluminides, containing noble metals such as Pt, Rh or Pd and/or reactive elements including, but not limited to, Y, Zr and Hf. The diffusion coating may be formed on the component in a number of different ways. In brief, the substrate may be exposed to aluminum, such as by a pack process or a chemical vapor deposition (CVD) process at elevated temperatures, and the resulting aluminide coating formed as a result of diffusion.
More particularly, a nickel aluminide (NiAl) diffusion coating, may be grown as an outer coat on a nickel-base superalloy by exposing the substrate to an aluminum rich environment at elevated temperatures. The aluminum from the outer layer diffuses into the substrate and combines with the nickel diffusing outward from the substrate to form an outer coating of NiAl. Because the formation of the coating is the result of a diffusion process, it will be recognized that there are chemical gradients of Al and Ni, as well as other elements. However, Al will have a high relative concentration at the outer surface of the article which will thermodynamically drive its diffusion into the substrate creating a diffusion zone extending into the original substrate, and this Al concentration will gradually decrease with increasing distance into the substrate. Conversely, Ni will have a higher concentration within the substrate and will diffuse into the thin layer of aluminum to form a nickel aluminide. The concentration of Ni in the diffusion zone will vary as it diffuses outward to form the NiAl. At a level below the original surface, the initial Ni composition of the substrate is maintained, but the Ni concentration in the diffusion zone will be less and will vary as a function of distance into the diffusion zone. The result is that although NiAl forms at the outer surface of the article, a gradient of varying composition of Ni and Al forms between the outer surface and the original substrate composition. The concentration gradients of Ni and other elements that diffuse outwardly from the substrate and the deposited aluminum, Al, create a diffusion zone between the outer surface of the article and that portion of the substrate having its original composition. Of course, exposure of the coated substrate to an oxidizing atmosphere typically results in the formation of an alumina layer over the nickel aluminide coating.
A platinum aluminide (PtAl) diffusion coating also may be formed by electroplating a thin layer of platinum over the nickel-base substrate to a predetermined thickness. Then, exposure of the platinum to an aluminum-rich environment at elevated temperatures causes the growth of an outer layer of PtAl as aluminum diffuses into and reacts with the platinum. At the same time, Ni diffuses outward from the substrate changing the composition of the substrate, while aluminum moves inward into and through the platinum into this diffusion zone of the substrate. Thus, complex structures of (Pt,Ni)Al are formed by exposing a substrate electroplated with a thin layer of Pt to an atmosphere rich in aluminum at elevated temperatures. As the aluminum diffuses inward toward the substrate and Ni diffuses in the opposite direction into the Pt creating the diffusion zone, PtAl2 phases may precipitate out of solution so that the resulting Pt—NiAl intermetallic matrix may also contain the precipitates of PtAl2 intermetallic. Precipitation of PtAl2 occurs if Al levels above a certain level are achieved; below this level, the coating is considered single-phase (Pt,Ni)Al. As with the nickel aluminide diffusion coating, a gradient of aluminum occurs form the aluminum rich outer surface inward toward the substrate surface, and a gradient of Ni and other elements occurs as these elements diffuse outward from the substrate into the aluminum rich additive layer. Here, as in the prior example, an aluminum rich outer layer is formed at the outer surface, which may include both platinum aluminides and nickel aluminides, while a diffusion layer below the outer layer is created. As with the nickel aluminide coating, exposure of the coated substrate to an oxidizing atmosphere typically results in the formation of an outer layer of alumina. Suitable aluminide coatings also include the commercially available Codep aluminide coating, one form of which is described in U.S. Pat. No. 3,667,985, used alone or in combination with a first electroplate of platinum, among other suitable coatings.
The overall thickness of the diffusion coating may vary, but typically may not be greater than about 0.0045 inches (4.5 mils) and more typically may be about 0.002 inches–0.003 inches (2–3 mils) in thickness. The diffusion layer, which is grown into the substrate, typically may be about 0.0005–0.0015 inches (0.5–1.5 mils), more typically, about 0.001 inches (1 mil) thick, while the outer additive layer comprises the balance, usually about 0.001–0.002 inches (1–2 mils). For example, a new make component may have a diffusion bond coat of about 0.0024 inches (about 2.4 mils) in thickness, including an additive layer of about 0.0012 inches (1.2 mils) and a diffusion zone of about 0.0012 inches (about 1.2 mils).
The weight of the blade 10 with bond coat 20 may be represented by w0. Ceramic thermal barrier coating 22 or other suitable ceramic material may then be applied over the bond coat 20. Ceramic thermal barrier coating 22 may comprise fully or partially stabilized yttria-stabilized zirconia and the like, as well as other low conductivity oxide coating materials known in the art. Examples of other suitable ceramics include about 92–93 weight percent zirconia stabilized with about 7–8 weight percent yttria, among other known ceramic thermal barrier coatings. The ceramic thermal barrier coating 22 may be applied by any suitable means. One preferred method for deposition is by electron beam physical vapor deposition (EB-PVD), although plasma spray deposition processes also may be employed for combustor applications. The density of a suitable EB-PVD applied ceramic thermal barrier coating may be 4.7 g/cm3, and more particular examples of suitable ceramic thermal barrier coatings are described in U.S. Pat. Nos. 4,055,705, 4,095,003, 4,328,285, 5,216,808 and 5,236,745 to name a few. The ceramic thermal barrier coating 22 may have a thickness (t) of between about 0.003 inches (3 mils) and about 0.010 inches (10 mils), more typically on the order of about 0.005 inches (5 mils) prior to engine service. The design thickness and that manufactured may vary from location to location on the part to provide the optimal level of cooling and balance of thermal stresses. The weight of the blade 10, including bond coat 20 and ceramic thermal barrier coating 22 may be represented by w1.
The afore-described coated component, meeting the aerodynamic dimensions intended by design, when entered into service is thus exposed to high temperatures for extended periods of time. During this exposure, the bond coat 10 may grow through interdiffusion with the substrate alloy. The extent of the interdiffusion may depend on the diffusion couple (e.g. coating Al levels, coating thickness, substrate alloy composition (Ni- or Co-based)), and temperature and time of exposure.
In accordance with an aspect of the repair process of the present invention, the above coated blade 10, which has been removed from engine service may be first inspected to determine the amount of wear on the part, particularly with respect to any spallation of the outer ceramic thermal barrier coating 22. Inspection may be conducted by any means known in the art, including visual and flurosecent penetrant inspection, among others. If necessary, the tip may be conventionally repaired to restore part dimensions.
Next, if needed, the outer ceramic thermal barrier coating 22 may be removed from the blade 10, by means known in the art, including chemical stripping and/or mechanical processes. For example, the ceramic thermal barrier coating 22 may be removed by known methods employing caustic autoclave and/or grit blasting processes. The ceramic thermal barrier coating 22 also may be removed by the processes described in U.S. Pat. No. 6,544,346, among others. All patents and applications referenced herein are incorporated by reference.
After removal of the ceramic thermal barrier coating 22, cleaning processes may be employed as described above to remove residuals. The blade 10 may then be weighed using a conventional apparatus such as a scale or balance, and its weight denoted by w2. The blade 10 also may be inspected at this stage, for example, by FPI techniques or other nondestructive techniques to further determine the integrity of the blade 10.
The underlying bond coat 20 may then be removed from blade 10 using methods known in the art. However, prior to removal of the above bond coat 20, if desired, conventional masking techniques may be employed to mask internal features of the blade 10 and protect any internal coating from removal. For example, a high temperature wax capable of withstanding the chemicals and temperatures employed in the bond coat removal step may be injected into the internal portion of the blade 10.
After any desired masking, mechanical processes such as the use of abrasive materials or chemical processes such as aqueous acid solutions, typically a mixture of nitric and phosphoric acids, may be employed to remove or strip off the underlying bond coat 20. In the case of metallic coatings based on aluminum, chemical etching wherein the article is submerged in an aqueous chemical etchant dissolving the coating as a result of reaction with the etchant may be employed. Accordingly, during the removal process about 1–3 mils of the interdiffused underlying base metal substrate may be removed thereby resulting in a decrease in airfoil wall thickness. The additive layer of the bond coat 20, typically about 1–2 mils, also may be removed.
After complete coating removal of the ceramic thermal barrier coating 22 and underlying bond coat 20, any employed maskant also may be removed. High temperature exposure in vaccum or air furnaces, among other processes may be employed. The part may be conventionally cleaned to remove residuals. For example, water flushing may be employed, among other cleaning techniques. The blade 10, now having its previously applied thermal barrier coating system 18 removed, may then be weighed again. This new weight may be denoted by w3. Accordingly, w3 will be less than w2. The difference, w2−w3, may thus represent the weight of removed bond coat 20 plus the weight of the underlying substrate removed during the stripping of the bond coat 20.
Welding/EDM and other processes also may be performed, as needed, to repair any defects in the underlying substrate, such as repair and reshaping of tip dimensions.
Bond coat 20 may then be reapplied to the blade 10 using about the same techniques and thickness as previously applied prior to the engine service. In one embodiment, the bond coat 20 is a diffusion coating, which is about the same composition and thickness as the previously removed diffusion coating. After re-application of the bond coat 20, the blade 10 may be weighed again to determine the weight margin remaining. The weight of the part with the newly applied bond coat may be denoted by w4. Alternatively, the reapplied bond coat may comprise any suitable bond coat applied to about the same thickness as the prior bond coat 20, and may not necessarily comprise the same composition as prior bond coat 20.
The weight/thickness margin remaining may then be used to determine the thickness in which to apply the ceramic thermal barrier coating 22 in order to restore airfoil dimensions without suffering a weight penalty. In one embodiment, the measurement of the original base metal thickness may be employed. This thickness may be physically measured using techniques known in the art, prior to application of any coatings. For example, nondestructive means such as ultrasound, x-ray analysis and CAT scan devices may be employed, among others. The original base metal thickness also may be known from design specifications of the component. Similarly, the thickness of the base metal after removal of the bond coat may be measured. The base metal thickness loss, Δt, as a result of bond coat removal, may be determined by comparing the original base metal thickness of the component to the measured thickness of the base metal after removal of the bond coat. The difference in measured thickness represents Δt.
Similarly, after bond coat stripping, the part's outer dimensions may be measured using co-ordinate measuring machines (CMM) or light gages. The three dimensional information from the engine exposed part may be compared to the original design intent. The average difference in dimensions may be used as Δt.
Alternatively, using combinations of the weight measurements w0, w1, w2, w3, w4, the amount of removed base metal may be determined. For example, w0–w4 may be used to determine the weight of the removed base metal, assuming that about the same bond coat 20 at about the same thickness is reapplied. The density of the removed base metal material will vary depending upon the particular alloy employed. However, the density of the superalloy will typically be greater than that of the ceramic layer. Accordingly, the mass change may be correlated to the area of stripped bond coating and density of the base metal. The base metal thickness loss, Δt, is related to the base metal alloy density and stripped area, which are known values. The thickness, Δt, may be determined by: Δt=(weight removed)/(area×density).
Similarly, if a different bond coat is to be reapplied, the weight of removed base metal may be readily determined by, for instance, w2−w3 minus an assumed weight for the original coating additive layer (e.g. additive layer density may be about 6.1 g/cm3 and about 7.5 g/cm3 for NiAl and PtAl diffusion coatings, respectively; e.g. weight of additive layer (wadd)=1.2 mils×area×specific additive layer density). The value of w2−w3−wadd=may be used in the above Δt calculation. This thickness may need to be increased or decreased depending on the relative difference in additive layer between the original coating and the alternative bond coat material.
Once determined, the base metal thickness loss, Δt, may be added to the original ceramic thermal barrier coating thickness, t. Accordingly, the ceramic thermal barrier coating 22 may then be applied at the newly determined greater thickness of t+Δt, where Δt also represents the additional thickness of the ceramic added to compensate for the base metal loss of the substrate as a result of the above-bond coat removal/stripping procedures. For example, the value of Δt may be between about 1 mil (0.001 inches) and about 3 mils (0.003 inches), and more typically at least about 2 mils (0.002 inches).
The coating 22 or other suitable ceramic thermal barrier coating may be applied to the new thickness using conventional methods, and one skilled in the art would understand how to adjust the coating process/time to achieve the new thickness. For example, a new targeted part weight gain may be established based on the new thickness, Δt+t using regression curves. The TBC producer may accomplish the new weight gain by adding time to the coating operation in a prescribed way. To establish regression curves, for example, numerous parts may be coated with the ceramic thermal barrier coating and weight measurements taken at various coating thicknesses to determine that for a particular resultant weight gain, a particular ceramic thermal barrier coating thickness will need to be applied. Thus, if a particular resultant weight gain (targeted weight gain) is desired, the ceramic thermal barrier coating may be applied to the predetermined thickness, which results in the targeted weight gain. The coating time may thus be adjusted to achieve the desired weight gain.
The recoated blade may be weighed, and this weight may be represented by w5. W5 will be less than w1 because of the added ceramic, which has a lower density than that of the removed base metal. Advantageously, this newly coated component has the restored dimensions to meet the original aerodynamic intent of the part and be within original allowable tolerances, as shown schematically in the process example set forth in FIG. 3, and does not suffer a weight penalty.
Applicants have advantageously determined how to increase the engine efficiency in contrast to the teachings of prior repair techniques. In particular, Applicants have determined how to increase engine efficiency by, for example, correlating the above weight measurements with that of the outer ceramic thermal barrier coating 22 to determine effective new thicknesses for application of the outer ceramic material. This process is surprising and in contrast to prior teachings.
The afore-described process also is applicable to repair and refurbish components more than once. In this case, care should be taken to measure and ensure that the thickness of the remaining base metal meets any minimum thickness design requirements.
While various embodiments are described herein it will be appreciated from the specification that various combinations of elements, variations or improvements therein may be made by those skilled in the art, and are within the scope of the invention.

## Claims

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, w0, and the component including the bond coat and the top thermal barrier coating thereon before engine operation has a weight, w1;
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, w2, after removal of the thermal barrier coating and before removal of the bond coat; and the component has a weight, w3, after complete removal of the thermal barrier coating system;
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 w4, to determine a weight margin remaining, wherein a combination of at least two of w0, w1, w2, w3 and w4 is employed to determine the amount of removed base metal and calculate a thickness in which to apply a top ceramic thermal barrier coating without incurring a weight penalty;
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 w5, wherein w5 is less than w1.

2. The method of claim 1, wherein the engine run component is a high pressure turbine blade, and coated airfoil contour dimensions of the coated component are restored.

3. The method of claim 1, wherein t is between about 3 mils and about 10 mils, and Δt is at least about 1 mil.

4. The method of claim 1, wherein the bond coat of a) and c) comprises a diffusion aluminide coating.

5. The method of claim 4, wherein the diffusion aluminide coating is a simple aluminide or a modified aluminide.

6. The method of claim 1, wherein the base metal substrate is a nickel-based single crystal superalloy.

7. The method of claim 1, wherein the base metal substrate is a nickel-based directionally solidified superalloy.

8. The method of claim 4, wherein the diffusion aluminide coating is a modified aluminide coating comprising a metal selected from the group consisting of Pt, Rh and Pd.

9. The method of claim 4, wherein the diffusion aluminide coating further comprising reactive elements.

10. The method of claim 1, wherein the ceramic thermal barrier coating comprising yttria stabilized with zirconia.

11. The method of claim 1, wherein the bond coat of a) and c) comprises a MCrAlY coating, wherein M is selected from the group consisting of iron, cobalt, nickel and mixtures thereof.

12. A method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore airfoil contour dimensions of the blade comprising:
a) providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy having thereon a thermal barrier coating system, the thermal barrier coating system comprising a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material, 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, w0, and the component including the bond coat and the top thermal barrier coating thereon before engine operation has a weight, w1;
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, w2, after removal of the thermal barrier coating and before removal of the bond coat; and the component has a weight, w3, after complete removal of the thermal barrier coating system;
c) reapplying the diffusion bond coat to the substrate, wherein the bond coat is reapplied to a thickness, which is about the same as applied prior to the engine operation; wherein after application of the bond coat the component is weighed, denoted by w4, to determine a weight margin remaining, wherein a combination of at least two of w0, w1, w2, w3 and w4 is employed to determine the amount of removed base metal and calculate a thickness in which to apply a top ceramic thermal barrier coating without incurring a weight penalty;
d) reapplying the 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 airfoil to airfoil throat distance to about that preceding the engine run so that the coated airfoil contour dimensions are restored to about the coated dimensions preceding the engine run, 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 w5, wherein w5 is less than w1.

13. The method of claim 12, wherein the nickel-based alloy has a density of about 8.64 g/cm3.

14. The method of claim 12, wherein the yttria stabilized zirconia material has a density of about 4.7 g/cm3.

15. The method of claim 1, wherein the component is an airfoil.

16. The method of claim 1, wherein the component is a static component.

17. The method of claim 16, wherein the static component is a vane.

18. A method for repairing a coated component, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the component comprising:
a) providing an engine run component including a base metal substrate made of a nickel-based alloy having thereon a thermal barrier coating system, the thermal barrier coating system comprising a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material, 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, w0, and the component including the bond coat and the top thermal barrier coating thereon before engine operation has a weight, w1;
b) inspecting the component;
c) removing completely the thermal barrier coating system by stripping, wherein a portion of the base metal substrate also is removed, the portion of the base metal substrate removed having a thickness, Δt; wherein the component has a weight, w2, after removal of the thermal barrier coating and before removal of the bond coat; and the component has a weight, w3, after complete removal of the thermal barrier coating system;
d) reapplying the diffusion bond coat to the substrate, wherein the bond coat is reapplied to a thickness, which is about the same as applied prior to the engine operation, followed by weighing the component to calculate Δt; wherein after application of the bond coat the component is weighed, denoted by w4, to determine a weight margin remaining, wherein a combination of at least two of w0, w1, w2, w3 and w4 is employed to determine the amount of removed base metal and calculate a thickness in which to apply a top ceramic thermal barrier coating without incurring a weight penalty; and
e) reapplying the 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 airfoil contour dimensions of the coated component are restored to about the coated dimensions preceding the engine run, wherein the thermal barrier coating of e) is applied at a thickness greater than the thermal barrier coating a); and weight of the component having the bond coat of d) and the thermal barrier coating of e) thereon is denoted by w5, wherein w5 is less than w1.