Abstract: Two constituent powders of a powder blend for thermal spraying are in the form of composite particles containing subparticles of nickel alloy and benoite for clearance control coatings. The composite particles are formed by spray drying. In one embodiment the volume percentage of metal in one constituent powder is at least 25% greater than in the other powder. In another embodiment the difference is about 10% by volume, and the alloy rich constituent has alloy subparticles sufficiently large to act as core particles to which the finer subparticles of bentonite are bonded.

Abstract: A thermal spray powder comprising particles with a central core of a material selected from the group consisting of zirconium oxide, magnesium oxide, hafnium oxide, cerium oxide, yttrium oxide and combinations thereof. The core then has discrete aluminum particles and silicon dioxide homogeneously disposed in a binder deposited thereon to form the thermal spray powder which may be thermal sprayed to produce an abradable and erosion resistant coating.

Abstract: A flame spray powder comprising particles with a central core of a material selected from the group consisting of zirconium oxide, magnesium oxide, hafnium oxide, cerium oxide, yttrium oxide and combinations thereof. The core then has discrete aluminum particles in a binder deposited therein to form the flame spray powder which may be flame sprayed produce an abradable and erosion resistant coating.

Abstract: A self-bonding flame spray wire capable of forming a readily grindable coating formed of a sheath of aluminum and a compacted powder core containing a major portion of nickel and stainless steel and a minor portion of aluminum and metal oxide. The core may contain from about 10 to 90 percent, and preferably about 61 percent, by weight nickel, about 10 to 90, and preferably 30, percent by weight stainless steel, from 1 to 10 percent by weight, and preferably 5 percent by weight, aluminum, from 1/4 to 10 percent by weight, and preferably 4 percent by weight, of the metal oxide which may, for example, be cobalt oxide or zirconium oxide, and is most preferably zirconium oxide.

Abstract: A self-bonding flame spray wire capable of forming a readily grindable coating formed of a sheath of aluminum and a compacted powder core containing a major portion of nickel and stainless steel and a minor portion of aluminum and metal oxide. The core may contain from about 10 to 90 percent, and preferably about 61 percent, by weight nickel, about 10 to 90, and preferably 30, percent by weight stainless steel, from 1 to 10 percent by weight, and preferably 5 percent by weight, aluminum, from 1/4 to 10 percent by weight, and preferably 4 percent by weight, of the metal oxide which may, for example, be cobalt oxide or zirconium oxide, and is most preferably zirconium oxide.

Abstract: A flame spray powder comprising particles having a core of nickel, iron, copper, cobalt or alloys thereof coated with a binder containing discrete particles of aluminum and substantially pure nickel. The core material should be present in amounts of 70-98, and preferably 80-94, weight percent of the total metal content of the powder. The core particles should range in size between -60 mesh and +3 microns, and preferably -100 mesh and +400 mesh. The core material is most preferably nickel, and the coating may, in addition to the aluminum and nickel, contain molybdenum.