Patent ID: 7547478

Claim:
A coated article comprising: a metallic substrate having a substrate composition and an original thickness; a metallic coating overlying and contacting the metallic substrate, wherein the metallic coating has a metallic-coating composition different from the substrate composition, wherein the metallic coating is a precipitation-strengthened nickel-base superalloy having less than about 10 percent by weight aluminum, is not a diffusion aluminide protective coating having above about 16 percent by weight aluminum and is not an MCrAIY-type overlay coating having above about 16 percent by weight aluminum, and wherein the substrate is a component of a gas turbine engine that has previously been in service without the metallic coating thereon, the metallic coating restoring a portion of the substrate to the original thickness, the metallic coating having a thickness of from about 0.003 inch to about 0.015 inch; and a protective coating overlying and contacting the metallic coating, wherein the protective coating comprises an aluminide diffusion coating layer overlying and contacting the metallic coating, wherein the aluminide diffusion coating layer comprises at least about 16 percent by weight aluminum and at least about 16 percent by weight of a platinum group metal; and a ceramic thermal barrier coating overlying and contacting the aluminide diffusion coating layer; wherein the article is dimensionally controlled.