Patent ID: 8916005

Claim:
A process of forming a diffusion aluminide coating on surfaces of a component, the process comprising: preparing a slurry consisting of a donor powder containing a metallic aluminum alloy having a melting temperature higher than aluminum, an activator powder that forms a reactive halide vapor with aluminum in the aluminum alloy, and a binder that consist of at least one organic polymer gel; applying the slurry to the surfaces of the component; and then heating the component to burn off the binder, vaporize and react the activator powder with the metallic aluminum to form the halide vapor, react the halide vapor at the surfaces of the component to deposit aluminum on the surfaces, and diffuse the deposited aluminum into the surfaces of the component to form a diffusion aluminide coating, wherein the binder burns off to form a readily removable residue, wherein the slurry consists of, by weight, about 35 to about 65% of the donor powder, about 1 to about 25% of the activator powder, and about 25 to about 60% of the binder.