CPC C23C 24/103 (2013.01) [C04B 41/009 (2013.01); C04B 41/52 (2013.01); C04B 41/89 (2013.01); C23C 4/10 (2013.01); C23C 4/12 (2013.01); C23C 14/08 (2013.01); C23D 5/005 (2013.01); F01D 5/282 (2013.01); F01D 5/284 (2013.01); F01D 5/288 (2013.01); F05D 2230/90 (2013.01); F05D 2300/211 (2013.01); F05D 2300/514 (2013.01); F05D 2300/6033 (2013.01); F05D 2300/611 (2013.01); F05D 2300/6111 (2013.01); Y02T 50/60 (2013.01)] | 20 Claims |
1. A method of forming a coated CMC component comprising:
forming an inner layer along at least a portion of a substrate, and
forming an outer layer along the inner layer by depositing a plurality of pre-condensed matter particles of a coating material that have been at least partially melted before impinging a surface and solidified thereon,
wherein the substrate comprises a ceramic composite,
wherein the inner layer comprises ceramic material, has a porosity of less than about 40% by volume, and is continuous along the outer layer, and
wherein the outer layer comprises a plurality of growth domains defined between domain boundaries, the plurality of growth domains comprising a comparatively high density of the coating material and the domain boundaries comprising a comparatively low density of the coating material, the domain boundaries defining respective gaps between the growth domains that are configured to accommodate expansion and shrinkage of the growth domains into the gaps.
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