Method for creating a textured bond coat surface

Abstract

A method for forming a textured bond coat surface (48) for a thermal barrier coating system (44) of a gas turbine component (34). The method includes selectively melting portions of a layer of alloy particles (16) with a patterned energy beam (20) to form successive layers of alloy material (16′, 16″) until a desired surface geometric feature (26) is achieved. The energy beam pattern may be indexed between layers to form a protruding undercut (28) in the geometric feature. The patterned energy beam may be formed by directing laser energy from a diode laser (30) through a cartridge filter (32). Particles of a flux material (18) may be melted along with the alloy particles to form a protective layer of slag (22) over the melted and cooling alloy material.

Dependencies are inferred from the claim text.