System and method for applying a metallic coating

1. A method for application of a metallic coating to a vane cluster including at least two cluster vanes, the method comprising:

applying a first layer of metallic coating within a portion of a total surface of the at least two cluster vanes; and

applying a second layer of metallic coating to substantially the total surface of the at least two cluster vanes.

2. The method of claim 1 , wherein the first and second layers of metallic coating comprise a metallic bond coat.

3. The method of claim 1 , wherein the portion comprises a non-line of sight area of the total surface.

4. The method of claim 1 , wherein the applying a first layer step comprises applying the first layer of metallic coating within the portion of the total surface of the at least two cluster vanes using a contact metal deposition process.

5. The method of claim 4 , wherein the contact metal deposition process comprises an electro-spark deposition process.

6. The method of claim 5 , wherein the electro-spark deposition process utilizes an electrode and comprises:

applying a first voltage to the electrode;

applying a second voltage to at least one of the at least two cluster vanes, wherein the first voltage is greater than the second voltage; and

touching the electrode to the portion of the total surface of the at least two cluster vanes.

7. The method of claim 6 , wherein the second voltage comprises ground.

8. The method of claim 6 , further comprising rotating the electrode while touching the electrode to the portion of the total surface of the at least two cluster vanes.

9. The method of claim 6 , further comprising supplying a shielding gas to an area where the electrode touches portion of the total surface of the at least two cluster vanes.

10. The method of claim 6 , wherein the step of touching the electrode to the portion of the total surface of the at least two cluster vanes is performed until a predetermined thickness of the first layer of metallic coating is deposited.

11. A vane cluster including at least two cluster vanes and comprising a metallic coating formed according to the method of claim 5 .

12. The method of claim 1 , wherein the step of applying the second layer of metallic coating is performed using a process selected from the group consisting of: low pressure plasma spray, electron beam physical vapor deposition, air spray, and electron beam directed vapor deposition.

13. A vane cluster including at least two cluster vanes and comprising a metallic coating formed according to the method of claim 12 .

14. The method of claim 1 , wherein the first layer is disposed beneath the second layer.

15. A vane cluster including at least two cluster vanes and comprising a metallic coating formed according to the method of claim 14 .

16. A vane cluster including at least two cluster vanes and comprising a metallic coating formed according to the method of claim 1 .

17. A vane cluster comprising:

a cluster platform;

a cluster shroud;

at least two cluster vanes extending between the cluster platform and the cluster shroud and defining a total surface;

a first layer of metallic coating disposed within a portion of the total surface of the at least two cluster vanes; and

a second layer of metallic coating disposed on substantially the total surface of the at least two cluster vanes.

18. The vane cluster of claim 17 , wherein the metallic coating comprises a metallic bond coat.

19. The vane cluster of claim 17 , wherein the first layer of metallic coating is applied within the portion of the total surface of the at least two cluster vanes using an electro-spark deposition process.

20. The vane cluster of claim 17 , wherein the first layer is disposed beneath the second layer.