Coating and coating process incorporating raised surface features for an air-cooled surface

A process of forming turbulators on a substrate surface of a gas turbine engine component, the process comprising the steps of:

• depositing a metallic coating material on the substrate surface of the component to form a first environmental coating layer having a substantially smooth surface;
• and then
• depositing the metallic coating material on the surface of the first environmental coating layer to form an outer environmental coating layer, the metallic coating material being deposited through openings in a masking screen so as to define raised turbulators on the outer environmental coating layer, the raised turbulators defining a surface of the outer environmental coating layer that is rougher than the surface of the first environmental coating layer, the outer environmental coating layer defining the outermost surface of the component.

A process of forming turbulators on a substrate surface of a gas turbine engine component, the process comprising the steps of:

• depositing first particles of beta-phase nickel aluminide on the substrate surface of the component to form a first environmental coating layer having a substantially smooth surface;
• and then
• depositing second particles of beta-phase nickel aluminide on the surface of the first environmental coating layer to form an outer environmental coating layer, the second particles being larger than the first particles such that the outer environmental coating layer is less dense than the first environmental coating layer and the outer environmental coating layer has raised turbulators that define a surface of the outer environmental coating layer that is rougher than the surface of the first environmental coating layer, the outer environmental coating layer defining the outermost surface of the component.

A component comprising:

• a first environmental coating layer on a surface of the component, the first environmental coating layer having an outer surface;
• and
• an outer environmental coating layer having raised surface features that define a surface of the outer environmental coating layer that is rougher than the outer surface of the first environmental coating layer, the raised surface features promoting heat transfer from the surface of the component.

A gas turbine engine component comprising:

• a first environmental coating layer formed of a metallic coating material and overlying a substrate surface of the component, the first environmental coating layer having a substantially smooth surface;
• and
• an outer environmental coating layer formed of the metallic coating material and overlying the surface of the first environmental coating layer, the outer environmental coating layer having raised columnar turbulators that define a surface of the outer environmental coating layer that is rougher than the surface of the first environmental coating layer, the raised turbulators promoting heat transfer from the substrate surface of the component, the outer environmental coating layer defining the outermost surface of the component.

A gas turbine engine component comprising:

• a first environmental coating layer formed of first particles of beta phase nickel aluminide and overlying a substrate surface of the component, the first environmental coating layer having a substantially smooth surface;
• and
• an outer environmental coating layer formed of second particles of beta-phase nickel aluminide and overlying the surface of the first environmental coating layer, the second particles of the outer environmental coating layer being larger than the first particles of the first environmental coating layer, the second particles defining raised turbulators on the outer environmental coating layer and causing the outer environmental coating layer to be less dense than the first environmental coating layer, the outer environmental coating layer defining the outermost surface of the component.