Patent ID: 8147982

Claim:
A turbine engine component prior to being installed in an operating turbine engine, comprising: a substrate of the turbine engine component having a surface; a bond coating formed on the surface of the substrate from a metal-based material with a cold spray process using a carrier gas, the bond coat containing entrained carrier gas and having substantially no pores; and a thermal barrier coating formed on the surface of the bond coat without causing the entrained carrier gas in the bond coat to form pores, the thermal barrier coating being adapted to be worn away during operation of the engine to expose the bond coating to a temperature of from about 980° C. (about 1800° F.) to about 1200° C. (about 2200° F.), to cause the entrained carrier gas to form pores in the bond coating so that the exposed bond coating has a level of porosity ranging from about 20% by volume of the coating to about 50% by volume of the coating.