Microwave brazing process for forming coatings

1. A process for forming a coating on a surface of a substrate, the process comprising:

forming a brazing paste comprising powder particles dispersed in a binder, the powder particles formed of a composition susceptible to microwave radiation and having a higher melting temperature than the substrate;

applying the brazing paste to the surface of the substrate;

subjecting the brazing paste to microwave radiation so that the powder particles within the brazing paste couple with the microwave radiation and are sufficiently heated to burn off the binder and then at least partially melt to form an at least partially molten layer on the surface of the substrate; and then

interrupting the microwave radiation and allowing the at least partially molten layer to cool and solidify to form the coating, wherein the coating has the composition of the powder particles and is bonded to the substrate.

2. The process according to claim 1 , wherein the powder particles are fully molten during the subjecting step and the coating is substantially nonporous.

3. The process according to claim 1 , wherein the powder particles are only partially molten during the subjecting step and the coating is a porous sintered coating.

4. The process according to claim 1 , wherein the surface of the substrate is formed of a metallic material.

5. The process according to claim 1 , wherein the surface of the substrate is formed of a ceramic material.

6. The process according to claim 1 , wherein the substrate and the composition of the powder particles are nickel-base alloys.

7. The process according to claim 1 , wherein the substrate and the composition of the powder particles are formed of different materials, and the coating has at least one property superior to the substrate, wherein the property is selected from the group consisting of corrosion resistance, oxidation resistance, wear resistance, erosion resistance, and low thermal conductivity.

8. The process according to claim 7 , wherein the brazing paste is applied to have a nonuniform thickness on the surface of the substrate, and the coating has a nonuniform thickness so that the at least one of the properties is superior in a first region of the coating as compared to a second region of the coating.

9. The process according to claim 1 , wherein the coating is more corrosion resistant than the substrate.

10. The process according to claim 1 , wherein the coating is more oxidation resistant than the substrate.

11. The process according to claim 1 , wherein the coating is more erosion resistant than the substrate.

12. The process according to claim 1 , wherein the coating has lower thermal conductivity than the substrate.

13. The process according to claim 1 , further comprising:

forming a second brazing paste comprising second powder particles dispersed in a second binder, the second powder particles having a second composition susceptible to microwave radiation; and then

applying the second brazing paste to a second surface of the substrate;

wherein during the subjecting step the second brazing paste is subjected to the microwave radiation so that the second powder particles within the second brazing paste couple with the microwave radiation and are sufficiently heated to burn off the second binder and then at least partially melt to form an at least partially molten second layer on the second surface of the substrate; and

wherein during the interrupting step the at least partially molten second layer cools and solidifies to form a second coating having a different composition than the coating.

14. The process according to claim 1 , wherein the binder is transparent to the microwave radiation.

15. The process according to claim 1 , wherein the powder particles have a maximum particle size of about 100 micrometers.

16. The process according to claim 1 , wherein the substrate is a portion of a gas turbine engine component.

17. The process according to claim 1 , wherein the powder particles in the brazing paste have a maximum particle size of about 100 micrometers.

18. The process according to claim 1 , wherein the powder particles in the brazing paste do not contain any element capable of serving as a melting point depressant, in an amount that exceeds the level for that element in the material of the substrate.

19. The process according to claim 18 , wherein the substrate comprises a nickel-base superalloy; and the brazing paste comprises less than 1 wt. % of boron and silicon, individually.

20. A process for forming a coating on a surface region of a gas turbine engine component formed of a nickel-base superalloy, the process comprising:

forming a brazing paste comprising powder particles dispersed in a binder, the powder particles being formed of a nickel-base alloy having a higher melting temperature than the substrate and optionally contains melting point depressants but in amounts not exceeding any amounts of the melting point depressants in the nickel-base superalloy of the surface region;

applying the brazing paste to the surface region of the component;

subjecting the brazing paste to microwave radiation so that the powder particles within the brazing paste couple with the microwave radiation and are sufficiently heated to burn off the binder and then melt to form a molten layer on the surface of the substrate; and then

interrupting the microwave radiation and allowing the molten layer to cool and solidify to form the coating, wherein the coating has the metallic composition of the powder particles and is metallurgically bonded to the surface region.

21. The process according to claim 20 , wherein the coating has at least one property superior to the substrate.