Abstract: An apparatus for coating a work piece includes a process chamber, a coating material supply apparatus located at least partially within the process chamber for delivering a coating material to the work piece, a pre-heater assembly adjoining the process chamber, and a support for holding the work piece. The pre-heater assembly includes a housing that opens to the process chamber, a susceptor comprising a ceramic material positioned at least partially within the housing, and a pre-heater electron gun configured to configured to direct an electron beam at the susceptor such that the susceptor radiates heat toward the work piece. The support is movable to selectively move the work piece between a first position within the housing of the pre-heater assembly and a second position within the process chamber and outside the housing of the pre-heater assembly.

Abstract: A coating system includes a work piece, a coating delivery apparatus configured to apply a coating material to the work piece in a plasma-based vapor stream, and a first electron gun configured to direct a first electron beam at the plasma-based vapor stream for adding thermal energy to the coating material in the plasma-based vapor stream.

Abstract: An apparatus for coating a work piece includes a process chamber, a coating material supply apparatus located at least partially within the process chamber for delivering a coating material to the work piece, a pre-heater assembly adjoining the process chamber, and a support for holding the work piece. The pre-heater assembly includes a housing that opens to the process chamber, a thermal hood positioned within the housing and configured to reflect thermal energy for reflecting thermal energy toward the work piece. The support is movable to selectively move the work piece between a first position within the housing of the pre-heater assembly and a second position within the process chamber and outside the housing of the pre-heater assembly.

Abstract: An apparatus includes a work piece support for holding and selectively rotating a work piece, a coating delivery apparatus configured to apply a coating material to the work piece, a susceptor positioned adjacent to the work piece support, and a first electron gun configured to direct a first electron beam at the susceptor such that the susceptor radiates heat toward the work piece.

Abstract: A coating system includes a first work piece, a work piece support for holding the first work piece, a plasma-based coating delivery apparatus configured to apply a coating material to the first work piece in a plasma-based vapor stream, and a first electron gun configured to direct a first electron beam at the first work piece while the plasma-based coating delivery apparatus applies the coating to the first work piece for heating the first work piece being coated, wherein the first electron gun is configured to direct the first electron beam at a region of the first work piece facing away from the plasma-based coating delivery apparatus.

Abstract: An article includes a metallic substrate and a tri-layer thermal barrier coating that is deposited on the metallic substrate. The tri-layer thermal barrier coating includes an inner ceramic layer, an outermost ceramic layer relative to the metallic substrate, and an intermediate ceramic layer between the inner ceramic layer and the outermost ceramic layer. The inner ceramic layer and the outermost ceramic layer are composed of respective first and second ceramic materials and the intermediate ceramic layers composed of a third, different ceramic material. The inner ceramic layer has a first thickness, the outermost ceramic layer has a second thickness, and the intermediate ceramic layer has a third thickness that is greater than the first thickness and the second thickness.

Abstract: Systems and methods are described that monitor electron beam current and voltage. The systems and methods react to fault conditions such as arcing experienced during evaporation and deposition processes to shutdown and protect associated power supply equipment. The systems and methods may provide online beam current control to provide stable operation of e-beam guns during heating and melting modes of operation.

Abstract: An electron beam vapor deposition apparatus includes a coating chamber including a coating zone for depositing a coating on a work piece. A coating device includes at least one crucible for presenting at least one source coating material. The coating device includes a first deposition mode of depositing the at least one source coating material and a second deposition mode of depositing the at least one source coating material. At least one electron beam source evaporates the at least one source coating material for deposit onto the work piece. A controller is configured to control a speed of movement of the work piece in the coating zone during the coating operation in response to the first deposition mode and the second deposition mode.

Abstract: A physical vapor deposition apparatus includes first and second chambers. A first directed vapor deposition crucible is at least partially within the first chamber for presenting a first source material to be deposited on a work piece. A second directed vapor deposition crucible is at least partially within the second chamber for presenting a second, different source material to be deposited as a second coating on the work piece. At least one of the materials may be deposited as a coating.

Abstract: A method of processing an article includes heating the article in an atmosphere substantially free of oxygen to an oxidation temperature within a predetermined temperature range. The article includes a substrate and a bond coat disposed on the substrate. A partial pressure of oxygen is then established within the atmosphere after heating to the oxidation temperature. At least a portion of the bond coat oxidizes in the partial pressure of oxygen at the oxidation temperature to form a desired type of oxide to the substantial exclusion of forming other types of oxides. A ceramic coating is then deposited on the oxide.

Abstract: A coating device for use with an electron beam vapor deposition apparatus includes a crucible portion and a nozzle portion. The crucible portion includes a gas inlet port, a heating zone for presenting a source coating material to be heated, and a flow passage exposed to the heating zone and fluidly connected with the inlet port. The nozzle portion of the coating device includes an outlet orifice fluidly connected with the flow passage for jetting a coating stream from the coating device.

Abstract: A method for use with a coating process includes depositing a ceramic coating on a substrate within a coating chamber. Prior to depositing the ceramic coating, an electron beam source is used to heat a ceramic material. The ceramic material radiates heat to heat a substrate to an oxidation temperature to form an oxide layer on the substrate. A desired evaporation rate of the ceramic material is established during the heating to thereby provide an improved ceramic coating.

Abstract: A method for use in a coating process includes depositing a ceramic coating on a bond coat that is disposed on a substrate. Prior to depositing the ceramic coating, a desired surface roughness Rz is established to control a bonding strength between the bond coat and the ceramic coating.

Abstract: An electron beam vapor deposition apparatus includes a coating chamber having a first chamber section with a first coating zone for depositing a first coating and a second chamber section with a second coating zone for depositing a second coating. At least one electron beam source is associated with the first chamber section and the second chamber section. A first crucible is adjacent to the first coating zone for presenting a first source coating material, and a second crucible is adjacent to the second coating zone for presenting a second source coating material. A transport is operative to move a work piece between the first coating zone of the first chamber section and the second coating zone of the second chamber section.

Abstract: A deposition apparatus includes a coating chamber and a coating zone within the coating chamber for coating work pieces. A heating source heats the coating zone, and a thermal hood within the coating chamber is located adjacent to the coating zone for controlling a temperature of the coating zone.

Abstract: Physical vapor deposition is utilized to deposit repair material on Ti alloy turbine components.

Abstract: Physical vapor deposition is utilized to deposit repair material on Ti alloy turbine components.

Abstract: The subject invention relates generally to a novel method of recycling gelatin-based encapsulation waste material and, more specifically, to a process for the recovery and purification of gelatin and softening agents therefrom. In the preferred embodiment, deionized water is added to the waste material thereby forming an aqueous solution of gelatin and glycerine dispersed within the remaining oil and residual active-ingredient components of the waste material. Extraction methods are employed under specific conditions to effect separation of the bottom aqueous phase from the upper oil phase. The lower phase is hot filtered to remove any remaining traces of oil or other contaminants and the filtrate is then charged to a concentration vessel adapted for vacuum distillation. The water solvent is thus removed under specific thermal and atmospheric conditions until the desired concentration of gelatin and glycerine is achieved.

Abstract: Disclosed are coatings which are improved by a special peening process. Uniform sized spherical steel shot, in the range 1-2.5 mm is impacted at uniform low velocities onto a coated workpiece. Peening intensities are in the range 0.30-0.60 mm N. MCrAlY high temperature coatings are particularly improved, with densities of the order of 99 percent. Physical vapor desposited coatings have surface finishes of the order of 30.times.10.sup.-6 inch AA (Arithmetic Average) and plasma sprayed coatings have finishes of the order of 100.times.10.sup.-6 inch AA compared to unpeened finishes of 50-60.times.10.sup.-6 inch AA and 200-300.times.10.sup.-6 AA respectively.

Abstract: In shot peening apparatus, a device is provided for sensing shot peening intensity and the uniformity of shot flow. It is basically comprised of a detector plate mounted on a cantilevered arm; torque created at the arm mounting due to the impact of shot is measured with a transducer. The detector is mounted on a structure adapted to translate the detector through a large shot peening zone. The invention is especially suited for assuring consistency in a process wherein uniform spherical shot is gravity accelerated to impact a workpiece with uniform velocity.