Erosion and corrosion resistant protective coatings for turbomachinery

An erosion and corrosion resistant protective coating for turbomachinery applications, comprising:

• at least one ceramic or metal-ceramic coating segment deposited on a surface of a conductive metal substrate subjected to a pre-deposition treatment by at least blasting to provide the surface of the conductive metal substrate with texture, each ceramic or metal-ceramic coating segment being formed by concurrent condensation of ion bombardment from metal-gaseous plasma flow and at least 95% ionized metal atoms, wherein, at least during deposition of the first micron of the at least one ceramic or metal-ceramic coating segment, the deposition rate of metal ions is at least 3 μm/hr while kinetic energy of metal ions is at least 5 eV upon deposition, each coating segment having a thickness of at least about 5 μm;
• and
• an array of dome-like surface structures with a dome width of about 0.01 μm to about 30 μm.

An erosion and corrosion resistant protective coating for turbomachinery applications, comprising:

• at least one coating segment each being ceramic or metal-ceramic and having thickness of at least about 5 μm and hardness in range between about 0.3 GPa and about 80 GPa;
• the erosion and corrosion resistant coating having roughness characterized by Ra<1 μm, and dome-like structures with dome width between about 0.01 μm and about 30 μm.