Patent ID: 7842402

Claim:
A method of fabricating a machine component comprising: providing a machine component having a substrate including a surface region; forming a thermal barrier coating (TBC) system over the component comprising forming at least one TBC bond coat layer over the substrate surface region, wherein the at least one TBC bond coat layer is a nickel-chromium-aluminum-yttrium (NiCrAlY) composition having silicon (Si), hafnium (Hf) and less than 10 weight percent (wt %) cobalt (Co), wherein the at least one TBC bond coat layer comprises at least one oxygen active element selected from the group consisting of iridium, osmium, palladium, platinum, rhodium, and ruthenium; and distributing Si substantially uniformly within the at least one TBC bond coat layer such that: localized weight percents of Si do not exceed a predetermined weight percent of approximately 4.0%; and formation of SiO 2 is facilitated to be reduced.