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Abstract

A method and apparatus for forming a coating on a surface of a superalloy substrate area of a gas turbine engine component, and the component produced by the method, includes providing a slurry with selected metal powders suspended in a silane containing solution, applying the slurry by brushing, spraying or 3D printing using a piezoelectric dot matrix printhead to the superalloy substrate, drying the applied slurry, and depending on the aluminum content desired in the coating, including a sufficient amount of aluminum in the slurry or aluminiding the coated component. The method and apparatus can be used to obtain components having different superalloy coating thicknesses or compositions in different areas of the component based on the particular operating environment for each area with a single heat treatment and/or aluminiding cycle for obtaining the different coatings.

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