Patent ID: 7371426

Claim:
A method for repairing a coated component, which has been exposed to engine operation, to produce a repaired component without a weight penalty comprising: a) providing an engine run component including a base metal substrate having thereon a bond coat; b) removing the bond coat, wherein a portion of the base metal substrate between about 1-3 mils in thickness also is removed to create a remaining base metal substrate of reduced thickness; c) applying a lower growth environmental bond coating directly to the remaining base metal substrate comprising an alloy having an aluminum content of about 10 atomic percent, wherein the lower growth environmental bond coating and the remaining base metal substrate of the component interact to form a diffusion zone, and upon subsequent repair of the component, less than about 3 mils in thickness of the remaining base metal substrate is removed because of less environmental coating growth into the substrate than the prior bond coat, thereby extending component life and increasing repairability of the component, wherein the lower growth environmental bond coat has a density less than density of the prior bond coat and the repaired component does not incur a weight penalty in that the repaired component does not weigh more than the component prior to repair.