A coating process is provided. The coating process includes positioning a component within an enclosed coating system, the enclosed coating system including a coating apparatus, applying a first coating over at least a portion of the component, then robotically applying a mask to the component, then
A coating process is provided. The coating process includes positioning a component within an enclosed coating system, the enclosed coating system including a coating apparatus, applying a first coating over at least a portion of the component, then robotically applying a mask to the component, then applying a second coating over at least the portion of the component. The component remains within the enclosed coating system throughout the process. Another process also includes removing a first coating head portion of the coating apparatus after applying the first coating and replacing the first coating head portion with a masking head portion, then removing the masking head portion after robotically applying the mask to the component and replacing the masking head portion with a second coating head portion.
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1. A coating process 100, comprising: positioning a component 101 within an enclosed coating system 103, the enclosed coating system 103 including a coating apparatus 130;applying a first coating 106 over at least a portion 105 of the component 101; thenrobotically applying a mask 107 to the compone
1. A coating process 100, comprising: positioning a component 101 within an enclosed coating system 103, the enclosed coating system 103 including a coating apparatus 130;applying a first coating 106 over at least a portion 105 of the component 101; thenrobotically applying a mask 107 to the component 101; thenapplying a second coating 108 over at least the portion 105 the component 101;wherein the component 101 remains within the enclosed coating system 103 throughout the coating process 100. 2. The coating process 100 of claim 1, wherein the applying of the first coating is selected from the group consisting of high-velocity oxygen fuel spraying, air-plasma spraying, high-velocity air fuel spraying, vacuum plasma spraying, electron-beam physical vapor deposition, chemical vapor deposition, ion plasma deposition, combustion spraying with powder or rod, cold spraying, sol gel, electrophoretic deposition, polymer derived ceramic coating, vacuum-coating application, curtain-coating application, brush-application, roll-coat application, agglomeration and sintering followed by spray drying, and combinations thereof. 3. The coating process 100 of claim 1, wherein the applying of the second coating is selected from the group consisting of high-velocity oxygen fuel spraying, air-plasma spraying, high-velocity air fuel spraying, vacuum plasma spraying, electron-beam physical vapor deposition, chemical vapor deposition, ion plasma deposition, combustion spraying with powder or rod, cold spraying, sol gel, electrophoretic deposition, polymer derived ceramic coating, vacuum-coating application, curtain-coating application, brush-application, roll-coat application, agglomeration and sintering followed by spray drying, and combinations thereof. 4. The coating process of claim 1, wherein the applying of the first coating comprises high-velocity oxygen fuel spraying and the applying of the second coating comprises air-plasma spraying. 5. The coating process 100 of claim 1, further comprising removing a first coating head portion 109 of the coating apparatus 130 after the applying of the first coating 106 and replacing the first coating head portion 109 with a masking head portion 111 prior to the robotically applying the mask 107. 6. The coating process 100 of claim 5, wherein the masking head portion 111 includes a device selected from the group consisting of an application device, a curing device, and combinations thereof. 7. The coating process 100 of claim 6, wherein the application device is selected from the group consisting of a syringe, a printing device, a spray device, and combinations thereof. 8. The coating process 100 of claim 6, wherein the curing device is selected from the group consisting of an ultraviolet curing device, a thermal curing device, and combinations thereof. 9. The coating process 100 of claim 5, wherein the masking head portion 111 includes a location device selected from the group consisting of a laser, a structured laser scanner, an infrared detector, an electromagnetic probe, a visually-aided mechanism for location detection, and combinations thereof. 10. The coating process 100 of claim 5, wherein the masking head portion 111 includes a visually-aided mechanism for location detection. 11. The coating process 100 of claim 1, further comprising applying at least one additional coating layer over at least the portion 105 of the component 101. 12. The coating process 100 of claim 1, wherein the mask 107 includes a material selected from the group consisting of a radiation-curable material, an adhesive, a silicon-based material, a ceramic material, a ceramic-like material, and combinations thereof. 13. The coating process 100 of claim 1, wherein the mask 107 includes a material selected from the group consisting of aluminum oxide, hafnium oxide, yttria-stabilized zirconium oxide, and combinations thereof. 14. The coating process 100 of claim 1, wherein the mask 107 includes metallic material. 15. The coating process 100 of claim 14, wherein the mask 107 is formed outside the enclosed coating system 103, and the robotically applying the mask 107 includes positioning the mask 107 over the component 101. 16. The process 101 of claim 1, further comprising removing a masking head portion 111 of the coating apparatus 130 after the robotically applying of the mask 107 and replacing the masking head portion 111 with a second coating head portion 113 prior to the applying of the second coating 108. 17. The coating process 100 of claim 1, wherein the component 101 is at a temperature above ambient temperature during at least a portion of the applying of the mask 107. 18. The process of claim 1, wherein the component 101 is at a temperature above a safe handling temperature during at least a portion of the applying of the mask 107. 19. A coating process 100, comprising: positioning a component 101 within an enclosed coating system 103;applying a first coating 106 over at least a portion 105 of the component 101 with a coating apparatus 130; thenremoving a first coating head portion 109 of the coating apparatus 130 and replacing the first coating head portion 109 with a masking head portion 111; thenrobotically applying a mask 107 to the component 101 with the coating apparatus 130; thenremoving the masking head portion 111 of the coating apparatus 130 and replacing the masking head portion 111 with a second coating head portion 113; and thenapplying a second coating 108 over at least a portion of the component 101 with the coating apparatus 130;wherein the component 101 remains within the enclosed coating system 103 throughout the coating process 100. 20. A coating process 100, consisting of: positioning a component 101 within an enclosed coating system 103;high-velocity oxygen fuel coating at least a portion 105 of the component 101 with a coating apparatus 130; thenremoving a coating head portion 109 of the coating apparatus 130 and replacing the coating head portion 109 with a masking head portion 111; thenrobotically applying a mask 107 to the component 101 with the coating apparatus 130; thenremoving the masking head portion 111 of the coating apparatus 130 and replacing the masking head portion 111 with an air-plasma head portion 113; and thenair-plasma spraying the component 101 with the coating apparatus 130.
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