Abstract: A braze material and method of brazing titanium metals. The material may consist of Ti, Ni, Cu Zr, PM and M where PM is a precious metal and M may be Fe, V, Cr, Co, Mo, Nb, Mn, Si, Sn, Al, B, Gd, Ge or combinations thereof, with the (Cu+PM)/Ni ratio around 0.9. Optionally, a second brazing may be performed to rebraze any braze joint that did not braze successfully. The second brazing material has a lower braze temperature than the first and may consist of a mixture of Ti, Ni, Cu, Zr PM and M with from 1-20 wt % more Zr, PM, M or combinations thereof than the first braze. The braze material may be placed on a base material, in a vacuum furnace, and heated to form a braze joint between the braze and base material. The heating step may occur from about 800-975° C. and over 3 to 15 minutes.

Abstract: A braze material and method of brazing titanium metals. The material may consist of Ti, Ni, Cu Zr, PM and M where PM is a precious metal and M may be Fe, V, Cr, Co, Mo, Nb, Mn, Si, Sn, Al, B, Gd, Ge or combinations thereof, with the (Cu+PM)/Ni ratio around 0.9. Optionally, a second brazing may be performed to rebraze any braze joint that did not braze successfully. The second brazing material has a lower braze temperature than the first and may consist of a mixture of Ti, Ni, Cu, Zr PM and M with from 1-20 wt % more Zr, PM, M or combinations thereof than the first braze. The braze material may be placed on a base material, in a vacuum furnace, and heated to form a braze joint between the braze and base material. The heating step may occur from about 800-975° C. and over 3 to 15 minutes.

Abstract: A durable protective coating may be formed by applying a thin layer of metastable alumina to a bond coating on a substrate. A thermal barrier coating may then be applied to the metastable alumina and the resulting part may be heat treated to transform the metastable alumina to a mixed alpha alumina having particles of the thermal barrier coating, such as zirconia in the case of an yttria stabilized zirconia thermal barrier coating, dispersed therein. The resulting thermal barrier coating may inhibit microbuckling of the thermally grown oxide scale that grows over time at the thermal barrier coating-bond coating interface.

Abstract: A protective coating for a component comprising a ceramic based substrate, and methods for protecting the component, the protective coating adapted for withstanding repeated thermal cycling. The substrate may comprise silicon nitride or silicon carbide, and the protective coating may comprise at least one tantalate of scandium, yttrium, or a rare earth element. The protective coating may further comprise one or more metal oxides. The coating protects the substrate from combustion gases in the high temperature turbine engine environment. The coating may be multi-layered and exhibits strong bonding to Si-based substrate materials and composites.

Abstract: A method for coating a surface of a component formed from aluminum or an alloy thereof includes the step of cold gas-dynamic spraying a powder material on the component surface to form a coating, the powder material comprising at least one alloy from the group consisting of titanium, a titanium alloy, nickel, a nickel alloy, iron, an iron alloy, aluminum, an aluminum alloy, copper, a copper alloy, cobalt, and a cobalt alloy. In one embodiment, the method further includes the step of heat treating the turbine component after the cold gas-dynamic spraying.

Abstract: A method for stabilizing a porous thermal barrier coating plasma sprayed on a substrate comprises the steps of immersing the porous thermal barrier coating in a sol gel comprising a metal oxide or precursor thereof, a solvent, and a surfactant, applying vacuum pressure to the sol gel to infiltrate the porous thermal barrier coating with the sol gel, and drying the sol gel to produce residual metal oxide particles in the porous thermal barrier coating.

Abstract: Platinum containing coatings for corrosion and oxidation protection of a substrate, and platinum electrodeposition methods for coating a substrate. The coating may comprise platinum and at least one supplementary constituent, and the method may involve co-electrodeposition of platinum and the supplementary constituent from a single electrolyte composition. The supplementary constituent may comprise chromium, an oxidation protective reactive element, or an alloy of chromium with a reactive element. Components protected by such coatings are also disclosed.

Abstract: A protective barrier coating system including a diffusion barrier coating and an oxidation barrier coating and method for use in protecting silicon-based ceramic turbine engine components. A complete barrier coating system includes a thermal barrier coating of stabilized zirconia and an environmental barrier coating of an alloyed tantalum oxide. The oxidation barrier coating includes a layer of metallic silicates formed on a substrate of silicon nitride or silicon carbide to be protected. The oxidation barrier coating can include silicates of scandium, ytterbia or yttrium. The oxidation barrier coating may also include an inner layer of Si2ON2 between the diffusion barrier and the metallic silicate layer. The oxidation barrier coating can be applied to the substrate by spraying, slurry dipping and sintering, by a sol-gel process followed by sintering, by plasma spray, or by electron beam-physical vapor deposition.

Abstract: A component comprises a silicon-based substrate; and a protective coating for the substrate. The protective coating includes tantalum oxide (Ta2O5) and an additive for suppressing transformation from beta Ta2O5 to alpha Ta2O5.

Abstract: A component comprising a silicon-based substrate and a braze-based protective coating disposed on the silicon-based substrate. The braze-based coating comprises a brazed layer, wherein the brazed layer comprises at least one intermetallic compound. A scale layer may be formed on the brazed layer. An environmental barrier coating may be disposed directly on the brazed layer or directly on the scale layer. A thermal barrier coating may be disposed on the environmental barrier coating. Methods for making a Si-based component having a braze-based protective coating are also disclosed.

Abstract: Oxidation protection of a titanium-based alloy is provided with improved fatigue properties by a titanium aluminide coating of between 2 to 12 microns by diffusing the Al into the Ti at a temperature below the melting point of the Al. The coating is gas deposited and protects the titanium-based alloys from oxidation at high temperature utilization.

Abstract: A component comprises a silicon-based substrate; and a protective coating for the substrate. The protective coating includes tantalum oxide (Ta2O5) and an additive for suppressing transformation from beta Ta2O5 to alpha Ta2O5.

Abstract: A component comprising a silicon-based substrate and a diffusion barrier coating disposed on the silicon-based substrate. The diffusion barrier coating comprises an isolation layer disposed directly on the silicon-based substrate and at least one oxygen barrier layer disposed on the isolation layer. The oxygen barrier layer prevents the diffusion of oxygen therethrough, and prevents excessive oxidation of the silicon-based substrate. The isolation layer(s) prevent contaminants and impurities from reacting with the oxygen barrier layer. An environmental barrier coating may be disposed on the diffusion barrier coating, and a thermal barrier coating may be disposed on the environmental barrier coating. Methods for making a component having a diffusion barrier coating are also disclosed.

Abstract: Oxidation protection of a titanium-based alloy is provided with improved fatigue properties by a titanium aluminide coating of between 2 to 12 microns by diffusing the Al into the Ti at a temperature below the melting point of the Al. The coating is gas deposited and protects the titanium-based alloys from oxidation at high temperature utilization.

Abstract: A braze material and method of brazing titanium metals. The material may consist of Ti, Ni, Cu Zr, PM and M where PM is a precious metal and M may be Fe, V, Cr, Co, Mo, Nb, Mn, Si, Sn, Al, B, Gd, Ge or combinations thereof, with the (Cu+PM)/Ni ratio around 0.9. Optionally, a second brazing may be performed to rebraze any braze joint that did not braze successfully. The second brazing material has a lower braze temperature than the first and may consist of a mixture of Ti, Ni, Cu, Zr PM and M with from 1-20 wt% more Zr, PM, M or combinations thereof than the first braze. The braze material may be placed on a base material, in a vacuum furnace, and heated to form a braze joint between the braze and base material. The heating step may occur from about 800-975° C. and over 3 to 15 minutes.

Abstract: An environmentally and thermally protected component comprising a silicon-based ceramic or composite substrate and an environmental and thermal barrier coating disposed on the substrate. The environmental and thermal barrier coating comprises at least about 50 mole % AlTaO4. The composition of the environmental and thermal barrier coating may be adapted to provide excellent CTE (coefficient of thermal expansion) match with a substrate, such as a SiC-based ceramic or composite. Coating compositions of the invention have a stable crystalline structure at a temperature up to at least about 1550° C. Methods for preparing an environmentally and thermally protected component are also disclosed.

Abstract: A catalyst system for removing one or more components from a fluid stream includes a binder layer and a plurality of catalyst structures affixed to, and protruding from, the binder layer such that the catalyst structure surface is directly exposed to the fluid stream. Methods for preparing a catalyst system, and for selectively removing components from a fluid stream via a catalyst system are also disclosed.

Abstract: A component comprises a silicon-based substrate; and a protective coating for the substrate. The protective coating includes tantalum oxide (Ta2O5) and an additive for suppressing transformation from beta Ta2O5 to alpha Ta2O5.

Abstract: Oxidation protection of a titanium heat exchanger is provided by a titanium aluminide or solgel coating. The coating protects bare titanium and brazed surfaces of the heat exchanger.

Abstract: Methods and apparatus to make multilayer thermal barrier coatings for superalloy substrates such as turbine blades or vanes are disclosed. The methods produce non-homogeneous, nanometer-size, successive layers and a non-homogeneous interfacial layer without the use of baffles. Methods are also disclosed to use a lower cost metallic source and an oxygen bleed to create alumina or tantalum oxide vapor, to use a tantalum oxide or an alumina ingot and a low pressure inert gas feed to direct the vapor clouds, to use pulsed evaporation from a secondary vapor source to create non-homogeneous multilayer coating on non-rotated substrates, to use an electric bias to direct the vapor clouds, and to use a mechanical system to direct the vapor clouds or move and position the article to be coated in the clouds.