Method for repairing a thermal barrier coating and repaired coating formed thereby

摘要

A method of repairing a thermal barrier coating (16) on a component (10) designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method more particularly involves repairing a thermal barrier coating (16) on a component (10) that has suffered localized spallation (20) of the thermal barrier coating (16). After cleaning the surface area (22) of the component (10) exposed by the localized spallation (20), a ceramic paste (24) comprising a ceramic powder in a binder is applied to the surface area (22) of the component (10). The binder is then reacted to yield a ceramic-containing repair coating that covers the surface area of the component and comprises the ceramic powder in a matrix of a material formed when the binder was reacted. The binder is preferably a ceramic precursor material that can be converted immediately to a ceramic or allowed to thermally decompose over time to form a ceramic, such that the repair coating has a ceramic matrix. The repair method can be performed while the component (10) remains installed, e.g., in a gas turbine engine. Immediately after the reaction step, the gas turbine engine can resume operation during which the binder is further reacted/converted and the strength of the repair coating increases.