Coated articles and method for making

An article comprising:

• a substrate comprising a nickel-based superalloy, the nickel-based superalloy comprising a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers;
• and
• a coating disposed over the substrate at an interface, the coating comprising
• a) a MCrAlX composition,
• b) a plurality of particle boundaries, and
• c) a gamma phase of at least about 25 percent by volume of the coating, a beta phase in a range from about 10 percent to about 75 percent by volume of the coating, and a sigma phase where the sigma phase is less than 1 percent by volume of the coating;
• wherein at least about 50 volume percent of the coating is substantially free of rapid solidification artifacts;
• and
• wherein an interdiffusion zone extending from the interface into the substrate has a thickness of less than about 5 micrometers.