Patent ID: 6884461

Claim:
A method for applying a coating system to a substrate surface of an aircraft engine component to prevent interdiffusion between the substrate surface and a protective heat rejection layer applied over the substrate surface when the heat rejection layer is exposed to elevated temperatures, the method comprising the steps of: a) providing an aircraft engine component having at least one surface as a substrate surface; b) applying at least one layer of a solution comprising a carrier fluid, binder and aluminum over the substrate surface of the aircraft component; c) allowing the surface to dry; d) heating the coated substrate to a first preselected temperature for a first preselected time period in the substantial absence of oxygen to diffuse at least a portion of the aluminum into the substrate surface and to remove volatile portions of the at least one layer; e) then heating the coated substrate to a second preselected temperature for a second preselected time period in the presence of oxygen to form a continuous, tightly adherent oxidized aluminum layer on the substrate while removing any remaining volatile portions of the at least one layer; and f) applying at least one non-ceramic protective heat rejection layer selected from the group consisting of tantalum, platinum, palladium and rhodium directly on the oxidized aluminum layer.