Method for coating articles using a plasma transferred torchin non-transferred mode, and related methods for repairing and manufacturing articles

Abstract

A method for protecting an article from degradation, and a method for in-situ repair of a component of an assembly are presented, wherein the method for protecting comprises providing a substrate; providing a Plasma Transferred Arc (PTA) apparatus; setting the PTA apparatus to operate in a non-transferred arc mode; and disposing at least one coating on the substrate using the PTA apparatus in the non-transferred arc mode. The method for in-situ repair comprises providing a substrate, the substrate comprising a component of an assembly and coupled to the assembly; providing a PTA apparatus; welding the substrate using the PTA apparatus in a transferred arc mode to form a welded region on the substrate; setting the PTA apparatus to operate in a non-transferred arc mode; and disposing at least one coating on the welded region of the substrate using the PTA apparatus in the non-transferred arc mode, wherein the PTA apparatus is operated using a pilot arc power supply to dispose the at least one coating.

1 . A method for protecting an article from degradation, said method comprising: 
 providing a substrate;    providing a Plasma Transferred Arc (PTA) apparatus;    setting said PTA apparatus to operate in a non-transferred arc mode; and    disposing at least one coating on said substrate using said PTA apparatus in said non-transferred arc mode.    
     
     
         2 . The method of  claim 1 , wherein disposing said at least one coating comprises operating said PTA apparatus using a pilot arc power supply to dispose said at least one coating.  
     
     
         3 . The method of  claim 1 , further comprising welding said substrate using said PTA apparatus in a transferred arc mode to form a welded region on said substrate prior to disposing said at least one coating on said substrate using said PTA apparatus in said non-transferred arc mode.  
     
     
         4 . The method of  claim 3 , wherein disposing said at least one coating comprises disposing said coating on said welded region of said substrate.  
     
     
         5 . The method of  claim 1 , wherein providing said substrate comprises providing a substrate comprising at least one of a metal, a ceramic, and a plastic.  
     
     
         6 . The method of  claim 5 , wherein providing said substrate comprises providing a substrate comprising an alloy, said alloy comprising at least one of nickel, cobalt, iron, aluminum, and stainless steel.  
     
     
         7 . The method of  claim 1 , wherein providing said substrate comprises providing a component of a gas turbine assembly.  
     
     
         8 . The method of  claim 7 , wherein providing said component comprises removing said component from said turbine assembly.  
     
     
         9 . The method of  claim 7 , wherein disposing said at least one coating comprises disposing said at least one coating on said component wherein said component is coupled to said gas turbine assembly.  
     
     
         10 . The method of  claim 1 , wherein disposing said at least one coating comprises using a feedstock material in a form selected from the group consisting of powder, wire, rod, sheet, paste, and combinations thereof.  
     
     
         11 . The method of  claim 1 , wherein disposing said at least one coating comprises disposing at least one of a metal and a ceramic.  
     
     
         12 . The method of  claim 11 , wherein disposing said at least one coating comprises disposing a bond coat material.  
     
     
         13 . The method of  claim 12 , wherein disposing said bondcoat material comprises disposing a material comprising MCrAIX-type material, wherein M is at least one of nickel, cobalt, and iron, and wherein X is at least one of yttrium and zirconium.  
     
     
         14 . The method of  claim 12 , wherein disposing said bondcoat material comprises disposing material comprising an aluminide compound.  
     
     
         15 . The method of  claim 11 , wherein disposing said at least one coating comprises disposing a thermal barrier coating.  
     
     
         16 . The method of  claim 15 , wherein disposing said thermal barrier coating comprises disposing a material comprising yttria-stabilized zirconia.  
     
     
         17 . A method for protecting an article from degradation, said method comprising: 
 providing a substrate;    providing a PTA apparatus;    welding said substrate using said PTA apparatus in a transferred arc mode to form a welded region on said substrate;    setting said PTA apparatus to operate in a non-transferred arc mode; and    disposing at least one coating on said welded region of said substrate using said PTA apparatus in said non-transferred arc mode, wherein said PTA apparatus is operated using a pilot arc power supply to dispose said at least one coating.    
     
     
         18 . A method for in-situ repair of a component of an assembly, said method comprising: 
 providing a substrate, said substrate comprising a component of an assembly and coupled to said assembly;    providing a PTA apparatus;    welding said substrate using said PTA apparatus in a transferred arc mode to form a welded region on said substrate;    setting said PTA apparatus to operate in a non-transferred arc mode; and    disposing at least one coating on said welded region of said substrate using said PTA apparatus in said non-transferred arc mode, wherein said PTA apparatus is operated using a pilot arc power supply to dispose said at least one coating.