Abstract: A fluid tight, fully-densified, coating is prepared by a High Velocity Oxygen Fuel (“HVOF”) process that dilutes oxygen with an inert gas. The inert gas is pre-mixed with oxygen prior to the oxygen entering a combustion chamber. The resultant flame temperature is lowered a controlled amount to eliminate, minimize or reduce oxidation of power feedstock that is injected into the thermal spray torch. The ability to reduce the flame temperature allows a relatively smaller particle feedstock to be deposited without significant oxidation. The dilution process creates an as-deposited fully-dense, fluid tight coating.

Abstract: Polyurethane-based coatings which exhibit superior erosion and heat resistance combined with antifouling and chemical resistance that are useful for protection of metal components are provided. The coatings are characterized by enhanced particle erosion resistance and enhanced heat resistance and are derived from specific multicomponent slurry compositions.

Abstract: Hexavalent chromium-free slurry formulations which are suitable in the production of ceramic overlay coating systems are described. The formulations provide superior hot corrosion and heat oxidation protection for superalloy substrates. A basecoat slurry and topcoat slurry are provided. The basecoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:PO4 higher than about 1:3 with the incorporation of metal oxide particles. The topcoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:PO4 higher than about 1:3. Both of the basecoat slurry and the topcoat slurry are hexavalent chromium-free.

Abstract: This invention relates to a thin and texturized film that can be applied onto a non-smooth surface to improve hardness, corrosion resistance and wear resistance properties of the surface while maintaining the underlying profile of the non-smooth surface. An additive overlaying process can be employed to produce the thin and texturized film on the non-smooth surfaces without substantial alteration or degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The thin and texturized film fully covers the non-smooth in a uniform manner and maintains the surface profile.

Abstract: Hexavalent chromium-free slurries are provided that are capable of achieving a full cure at temperatures as low as 330-450 degrees F., thus making the coatings especially suitable for application on temperature sensitive base materials. The slurries are suitable in the production of protective coating systems formed by novel silicate-based basecoats that are sealed with novel phosphate-based topcoats. The coating systems exhibit acceptable corrosion and heat resistance and are capable of replacing traditional chromate-containing coating systems.

Abstract: A composition based on a certain chromium-free silicate-based binder is described. The composition is an aqueous solution of lithium-doped potassium silicate in combination with an aluminum or aluminum alloy powder, zinc powder or a combination thereof. The coatings of the present invention are capable of achieving a full cure at temperatures as low as 350-450 degrees F. by the inclusion of a colloidal solution of a nano-sized ceria, thus making the coatings especially suitable for application on temperature sensitive base materials.

Abstract: This invention relates to thermal spray coatings and processes onto non-smooth surfaces. The coating and processes can coat non-smooth surfaces without substantial degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The ability for coating fractional coverage to maintain the surface profile while maintaining wear resistance is unprecedented by conventional thermal spray processes.

Abstract: Novel slurry formulations and processes for forming improved protective coatings used in the hot section components of gas turbine engines are provided. The process includes a unique two-step deposition methodology whereby the required concentration of reactive element within an improved reactive element doped aluminide coating can be consistently produced in a reproducible manner.

Abstract: A novel dual layer mask formulation is provided. In particular, the mask has a unique composition that protects the integrity of an underlying chromide coating, prevents chromium depletion from the chromide coating and prevents a subsequent aluminide coating from being deposited thereon.

Abstract: Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require diffusion-stop-off masking. Prior to or after a localized slurry chromizing process of the present invention, a layer of a platinum-group-metal (PGM) is applied to produce a PGM-modified chromium diffusion coating onto selected regions of a substrate. A second coating can be selectively applied onto other regions of the substrate.

Abstract: A unique sequence of steps is provided to reduce contaminants along one or more surfaces and faces of gold evaporative sources without deleteriously impacting the structure of the gold evaporative sources. Edges are deburred; contaminants are successfully removed therealong; and surface smoothness is substantially retained. The resultant gold evaporative source is suitable for use in evaporative processes as a precursor to gold film deposition without the occurrence or a substantial reduction in the likelihood of spitting by virtue of significantly reduced levels of contaminants, in comparison to gold evaporative sources subject to a standard cleaning protocol.

Abstract: Unique and improved chromium coatings derived from modified chromium-containing slurry formulations are disclosed. The slurry formulation includes a combination of a selected halide activator and buffer material that synergistically interact with each other to form chromium diffusion coatings with improved microstructure in comparison to chromium diffusion coatings produced from conventional chromizing processes. The coatings may be locally applied in a controlled manner with accuracy onto various parts, including those having internal sections with complex geometries, without masking any portion thereof.

Abstract: A modified electroplated nickel-based metallic alloy coating and method of forming the same is provided. The electroplated coatings exhibit unique microstructure and composition which improves performance over conventional metallic materials. The coatings have significantly higher strength at elevated service temperatures.

Abstract: A unique sequence of steps is provided to reduce contaminants along one or more surfaces and faces of gold evaporative sources without deleteriously impacting the structure of the gold evaporative sources. Edges are deburred; contaminants are successfully removed therealong; and surface smoothness is substantially retained. The resultant gold evaporative source is suitable for use in evaporative processes as a precursor to gold film deposition without the occurrence or a substantial reduction in the likelihood of spitting by virtue of significantly reduced levels of contaminants, in comparison to gold evaporative sources subject to a standard cleaning protocol.

Abstract: A modular, rotisserie type tooling fixture assembly for use in a coating operation and method of its use are disclosed. The tooling fixture assembly includes an arbor or shaft and a retaining base with a plurality of anchor members disposed in a prescribed radial orientation from the center of the retaining base, the anchor members are uniquely configured or adapted to retain a plurality of workpieces to be coated. The tooling fixture assembly further comprises a unique workpiece masking arrangement that employs a unitary masking cap having a plurality of solid walls or surfaces adapted to cover portions of the plurality of workpieces in a masking relationship.

Abstract: A method for applying an aluminide coating includes applying an aluminum-based slurry onto an elongated member. The elongate member is introduced through an opening of a component and positioned within a cavity of the component at a location that is spaced apart from the internal surfaces of the component. Heat is applied to generate vaporized aluminum which diffuses into the internal surfaces of the component. Aluminum reacts with the internal surfaces to form an aluminide coating.

Abstract: The present invention relates to novel and improved high purity diffusion bonded copper (Cu) sputtering targets having a Cu purity level of 99.9999% (6N) or greater. The target assemblies of the present invention exhibit sufficient bond strength and microstructural homogeneity, both of which are properties previously considered mutually exclusive for conventional 6N Cu target assemblies. The grain structure is characterized by an absence of alloying elements and the bonded interface is generally flat without any type of interlayer or interlocking arrangement.

Abstract: This invention relates to a robot programming method that is carried out at a first location (i.e., teaching station) and a second location (i.e., application station). The second location is different from the first location. At the first location, teach data is prepared to teach motions to a robot to drive an end effector through a series of desired path points along a desired path of motion with respect to the application station. The teach data comprises at least one of robot position data elements and at least one of robot motion pattern data elements. At the second location, teach data is communicated to the robot and the robot is programmed in accordance with the teach data to drive the end effector through the series of desired path points along the desired path of motion with respect to the application station. This invention also relates to a robot programming system. The robot programming method and system are useful, for example, in thermal spray coating applications.

Abstract: A high surface finish, thermally stable, multilayer slurry-based overlay system suitable for use in a severe thermal environment is disclosed. The disclosed embodiments include a basecoat layer formed from a slurry comprising ceramic pigment filled phosphate-based binder, a second layer formed from a slurry comprising metal oxide pigment or ceramic oxide pigment filled phosphate-based binder, and an optional seal coat layer formed from a phosphate-based binder substantially free of pigments.

Abstract: Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require masking. A second coating can be selectively applied onto other regions of the substrate.