Patent ID: 8318251

Claim:
A method for creating a diffusion aluminide coating onto the surfaces of a honeycomb seal, the steps comprising: preparing a slurry comprising a powder containing a metallic aluminum alloy having a melting temperature higher than aluminum, an activator capable of forming a reactive halide vapor with aluminum in the aluminum alloy, and a binder containing at least one organic polymer; applying the slurry onto the surfaces of the honeycomb seal; heating the honeycomb seal to remove the binder, vaporize and react the activator with the metallic aluminum to form the halide vapor, react the halide vapor at the surfaces of the honeycomb seal to deposit aluminum on the surfaces, and diffuse the deposited aluminum into the surfaces of the honeycomb seal to form a diffusion aluminide coating, wherein the binder is removed to form a readily removable ash residue, wherein the temperature of said step of heating and the amount of activator used in said step of preparing are selected so that the diffusion aluminide coating is an outward-type.