Recoating process and recoated turbine blade

Abstract

Recoating process and recoated turbine blade are disclosed. The recoating process includes providing a coated turbine blade, then removing a portion of the thermal barrier coating system to form a partially-stripped turbine blade, then applying a bond recoat to the stripped region of the partially-stripped turbine blade; and then applying a thermal barrier recoat to the bond recoat to form a recoated turbine blade. The recoated turbine blade comprises the bond coating portion abutting the bond recoat, the thermal barrier coating portion abutting the thermal barrier recoat, and the stepped configuration. The coated turbine blade has a thermal barrier coating system positioned on a substrate. The partially-stripped turbine blade has a stripped region, a bond coating portion, a thermal barrier coating portion, and a stepped configuration.

What is claimed is:  
     
         1 . A recoating process, comprising:
 providing a coated turbine blade, the coated turbine blade having a thermal barrier coating system positioned on a substrate; then   removing a portion of the thermal barrier coating system to form a partially-stripped turbine blade having a stripped region; then   applying a bond recoat to the stripped region of the partially-stripped turbine blade; and then   applying a thermal barrier recoat to the bond recoat to form a recoated turbine blade.   
     
     
         2 . The recoating process of  claim 1 , wherein the thermal barrier coating system includes a thermal barrier coating and a bond coat. 
     
     
         3 . The recoating process of  claim 1 , wherein the removing is by water-jet stripping. 
     
     
         4 . The recoating process of  claim 1 , wherein the partially-stripped turbine blade comprises a bond coat portion and a thermal barrier coating portion prior to the applying of the bond recoat and the applying of the thermal barrier recoat. 
     
     
         5 . The recoating process of  claim 1 , wherein the partially-stripped turbine blade comprises a bond coat portion and is substantially devoid of a thermal barrier coating of the thermal barrier coating system prior to the applying of the bond recoat and applying of the thermal barrier recoat. 
     
     
         6 . The recoating process of  claim 1 , wherein the partially-stripped turbine blade has a stepped configuration. 
     
     
         7 . The recoating process of  claim 1 , comprising inspecting the partially-stripped turbine blade prior to applying the bond recoat. 
     
     
         8 . The recoating process of  claim 1 , wherein the applying of the bond recoat to the partially-stripped turbine blade includes applying a first bond recoat to the substrate and applying a second bond recoat to the first bond recoat. 
     
     
         9 . The recoating process of  claim 1 , wherein the applying of the bond recoat is devoid of masking. 
     
     
         10 . The recoating process of  claim 1 , wherein the applying of the bond recoat to the partially-stripped turbine blade does not apply the bond recoat outside of the stripped region of the partially-stripped turbine blade. 
     
     
         11 . The recoating process of  claim 1 , wherein the applying of the bond recoat to the partially-stripped turbine blade applies the bond recoat outside of the stripped region of the partially-stripped turbine blade. 
     
     
         12 . The recoating process of  claim 1 , wherein the applying of the thermal barrier recoat is devoid of masking. 
     
     
         13 . The recoating process of  claim 1 , wherein the applying of the thermal barrier recoat to the partially-stripped turbine blade does not apply the thermal barrier recoat outside of the stripped region of the partially-stripped turbine blade. 
     
     
         14 . The recoating process of  claim 1 , wherein the applying of the thermal barrier recoat to the partially-stripped turbine blade applies the thermal barrier recoat outside of the stripped region of the partially-stripped turbine blade. 
     
     
         15 . The recoating process of  claim 1 , wherein the recoated turbine blade comprises the bond recoat, and the bond recoat abuts a bond coating portion of the thermal barrier coating system. 
     
     
         16 . The recoating process of  claim 1 , wherein the recoated turbine blade comprises the thermal barrier recoat, and the thermal barrier recoat abuts a thermal barrier coating portion of the thermal barrier coating system. 
     
     
         17 . The recoating process of  claim 1 , wherein the recoated turbine blade has a stepped configuration. 
     
     
         18 . The recoating process of  claim 1 , wherein the removing of the portion of the thermal barrier coating system from the coated turbine blade is performed without removal of the coated turbine blade from a turbine system. 
     
     
         19 . A recoating process, comprising:
 providing a coated turbine blade, the coated turbine blade having a thermal barrier coating system positioned on a substrate; then   removing a portion of the thermal barrier coating system to form a partially-stripped turbine blade having a stripped region, a bond coating portion, a thermal barrier coating portion, and a stepped configuration; then   applying a bond recoat to the stripped region of the partially-stripped turbine blade; and then   applying a thermal barrier recoat to the bond recoat to form a recoated turbine blade;   wherein the recoated turbine blade comprises the bond coating portion abutting the bond recoat, the thermal barrier coating portion abutting the thermal barrier recoat, and the stepped configuration.   
     
     
         20 . A recoated turbine blade, comprising:
 a substrate;   a bond coat portion abutting a bond recoat;   a thermal barrier coating portion abutting a thermal barrier recoat; and   a stepped configuration of the bond coating portion, the bond coating, the thermal barrier portion, and the thermal barrier coating on the substrate;   wherein the bond coat portion and the thermal barrier coating portion include post-operational features.