Abstract: A composite material comprising a plurality of round particles bound together by a binding material. Each of the plurality of round particles includes a wear resistant element, an intermediate coating on the wear resistant element, and a round outer layer encapsulating the intermediate coating and the wear resistant element. The intermediate coating is metallurgically bonded to the wear resistant element, and is metallurgically bondable to the binding material.

Abstract: A cathode for a plasma gun includes a main body having a first end and a second end, wherein the first end has a protrusion. A method of using the cathode includes mounting the cathode inside a plasma gun and generating an arc discharge via the protrusion.

Abstract: Embodiments of an iron-based coating configured to be thermally sprayed are disclosed. The iron-based coatings can be fully readable, thus allowing for thickness measurements to be performed on the coating with standard magnetic measuring equipment. Further, the iron-based coating can have advantageous properties, such as high hardness, high wear resistance, and high adhesion strength.

Abstract: Disclosed herein are embodiments of hardfacing/hardbanding materials, alloys, or powder compositions that can have low chromium content or be chromium free. In some embodiments, the alloys can contain transition metal borides and borocarbides with a particular metallic component weight percentage. The disclosed alloys can have high hardness and ASTM G65 performance, making them advantageous for hardfacing/hardbanding applications.

Abstract: Thermal spray coating obtained from a thermal spray powder material containing at least one of Aluminum-containing particles, Magnesium-containing particles, and Titanium-containing particles mechanically alloyed to a transition metal. The coating includes Aluminum, Magnesium, or Titanium alloy portions alloyed to the transition metal. The thermal spray powder is obtained of Aluminum, Magnesium, or Titanium containing particles mechanically alloyed to a transition metal.

Abstract: The disclosed technology relates to a method of selecting a material composition and/or designing an alloy. In one aspect, a method of selecting a composition of a material having a target property comprises receiving an input comprising thermodynamic phase data for a plurality of materials. The method additionally includes extracting from the thermodynamic phase data a plurality of thermodynamic quantities corresponding to each of the materials by a computing device. The extracted thermodynamic quantities are predetermined to have correlations to microstructures associated with physical properties of the material. The method additionally includes storing the extracted thermodynamic quantities in a computer-readable medium. The method further includes electronically mining the stored thermodynamic quantities using the computing device to rank at least a subset of the materials based on a comparison of at least a subset of the thermodynamic quantities that are correlated to the target property.

Abstract: A thermal barrier coating (TBC) top coat which is a high entropy oxide (HEO) having a high configurational entropy, contains at least 5 different oxide-forming metallic cations, is a single phase or single crystalline structure, such as tetragonal or cubic over unexpectedly wide temperature ranges up to and beyond top coat operating temperatures of preferably at least 2300° F. The TBC top coats exhibit low thermal conductivity, good sintering resistance, excellent phase stability and good thermal cycling performance. At least five of the different oxide-forming metallic cations include: a) at least one of the transition metals: Sc, Y, Ti, Zr, V, Nb, Ta, Cr, Mo, W, Mn, Re, Fe, Ru, Co, Ni, Cu, or Zn, and/or at least one of the lanthanides La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb. Dy, Ho, Er, Yb, or Lu. One of the at least five different oxide-forming metallic cations may also comprise at least one of the alkaline-earth metals: Be, Mg, Ca, Sr, or Ba.

Abstract: A multi-layer coating arrangement includes an environmental barrier coating (EBC) over a substrate; and at least one dense vertically cracked (DVC) coating layer over the EBC. The at least one DVC layer is resistant to erosion, water vapor corrosion and to calcium-magnesium-aluminum-silicate (CMAS).

Abstract: Embodiments of an alloy that can be resistant to cracking. In some embodiments, the alloy can be advantageous for use as a hardfacing alloys, in both a diluted and undiluted state. Certain microstructural, thermodynamic, and performance criteria can be met by embodiments of the alloys that may make them advantageous for hardfacing.

Abstract: Embodiments of an alloy that can be resistant to cracking. In some embodiments, the alloy can be advantageous for use as a hardfacing alloys, in both a diluted and undiluted state. Certain microstructural, thermodynamic, and performance criteria can be met by embodiments of the alloys that may make them advantageous for hardfacing.

Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.

Abstract: Compositions are provided that exhibit an austenitic nickel microstructure. The compositions comprise Ni, Cr, Mo and at least one element selected from the group consisting of Al, Si, and Ti. Feedstock having the composition may be in the form of a cored wire or wires, a solid wire or wires, or a powder.

Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.

Abstract: Thermal sprayed coating made from a thermal spray powder material containing aluminum containing particles mechanically alloyed to a transition metal. The coating includes aluminum alloy portions alloyed to the transition metal. The thermal spray powder is made of aluminum containing particles mechanically alloyed to a transition metal.

Abstract: A thermo spray gun (10) includes at least one of; at least one removable nozzle tip (20) for spraying a coating material, at least one replaceable nozzle tip (20) for spraying a coating material, and at least one interchangeable nozzle tip (20) for spraying a coating material. A thermo spray gun system (1000) includes a thermal spray gun (10) and at least one mechanism (30/40) at least one of; storing at least one nozzle tip installable on the thermal spray gun and being structured and arranged to install at least one nozzle tip on the thermal spray gun. A method of coating a substrate (S) using a thermo spray gun (10) includes mounting at least one nozzle tip (20) on the thermo spray gun (10) and spraying a coating material with the at least one nozzle tip (20).

Abstract: An erosion and CMAS resistant coating arranged on a TBC coated substrate and including at least one porous vertically cracked (PVC) coating layer providing lower thermal conductivity and being disposed over a layer of MCrAlY wherein M represents Ni, Co or their combinations. At least one dense vertically cracked (DVC) erosion and CMAS resistant coating layer is deposited over the at least one PVC coating layer.

Abstract: Thermal spray powder including a metal and/or ceramic powder composition and porosity forming fibers and/or fiber agglomerates mixed within or with the powder composition. An exemplary TBC or abradable thermal spray coating can be made by the thermal spray powder.

Abstract: An erosion and CMAS resistant coating arranged on an EBC coated substrate includes at least one porous vertically cracked (PVC) coating layer providing CTE mitigation and being disposed over the EBC coated substrate. At least one dense vertically cracked (DVC) erosion and CMAS resistant coating layer is deposited over the at least one PVC coating layer.

Abstract: Disclosed herein are embodiments of alloys which can be particularly advantageous in twin wire arc spray methods for coating of a substrate. In some embodiments, a plurality of alloys can be used to form both hard and soft particles on a surface. In some embodiments, chromium can be minimized or eliminated.

Abstract: A braze alloy composition includes the formula: NiaFebPcBdSieCfXg wherein X is selected from the group consisting of Cu, Nb, Hf, Mo, W, V, Ta, Y, La, rare earth elements, Al, Ru, Pd, Cr, Mn, Co, Be, and mixtures thereof, a, b, c, d, e, f, and g are atom % of, respectively, Ni, Fe, P, B, Si, C, and X, and wherein 75?((a+b)?g)?90, a>b, 10?c+d+e+f?25, and g<10.