Methods for manufacturing components from articles formed by additive-manufacturing processes

A method for manufacturing a component from a first intermediate article formed by an additive manufacturing process, the method comprising:

• applying a coating material layer on at least one surface of the first intermediate article;
• diffusion heat treating the first intermediate article and the coating material layer to form a diffusion coating on the first intermediate article, the diffusion coating comprising a surface additive layer and a diffusion layer below the surface additive layer, the diffusion layer including an upper portion of a substrate of the first intermediate article;
• removing the diffusion coating including the upper portion of the substrate from the first intermediate article forming a second intermediate article having at least one enhanced surface;
• and
• optionally repeating the applying, diffusion heat treating, and removing steps at least once.

A method for manufacturing a component from a first intermediate article formed by an additive-manufacturing process, the first intermediate article comprised of a substrate and having at least one surface, the method comprising:

• applying an aluminum-containing coating material layer on the at least one surface, the substrate comprising a nickel-based superalloy;
• diffusion heat treating the first intermediate article and the aluminum-containing coating material layer to yield an aluminide diffusion coating on the first intermediate article, the aluminide diffusion coating comprising an aluminum-rich surface additive layer and a diffusion layer below the aluminum-rich surface additive layer, the diffusion layer including an upper portion of the substrate;
• removing the aluminide diffusion coating from the first intermediate article thereby forming a second intermediate article having at least one enhanced surface;
• and
• optionally repeating the applying, diffusion heat treating, and removing steps at least once.