Abstract: A bearing system includes a sleeve bearing supported on a shaft and a gear supported on the sleeve bearing. The shaft has an outer diameter shaft surface, the sleeve bearing has an inner diameter bearing surface and an outer diameter bearing surface, and the gear has a gear bore surface. At least one of the outer diameter shaft surface, the inner diameter bearing surface, the outer diameter bearing surface, and the gear bore surface includes an isotropic surface finish and a hard thin film over the isotropic surface finish. During a break-in period of operation of the bearing system, the hard thin film over the isotropic surface finish breaks in a counter surface of the bearing system to extend a hydrodynamic lubrication period of operation of the bearing system.

Abstract: A method and system for processing a bearing component to extend its useful life include using the component in the bearing assembly for a portion of its initial useful life and then removing the component from the bearing assembly. The surface of the removed component is subjected to isotropic finishing, after which a protective wear coating is applied to the surface of the component. Once processed, the used bearing component is reinstalled for use.

Abstract: A remanufactured planet carrier is disclosed having a first plate and a second plate spaced apart from and oriented generally parallel to the first plate. Supports join and support the first and second plates. The remanufactured planet carrier further has a plurality of first pin bores in the first plate and a plurality of second pin bores in the second plate. The first pin bores are parallel and generally aligned with the second pin bores. A cylindrical member extends from a central axis of the second plate away from the first plate with a shaft bore formed within the cylindrical member. The first and second pin bores and the shaft bore each have a surface layer with a hardness of at least about 180 BHN and a strength of at least about 500 MPa.

Abstract: A valve for use in an internal combustion engine is disclosed. The valve includes a stem connected to a fillet disposed between the stem and a seat face. A port receives the stem and accommodates a seat insert that engages the seat face when the valve is in a closed position. The seat insert is fabricated from a non-cobalt-based alloy or an iron-based alloy and the seat face is coated with a cobalt-based alloy or a nickel-based alloy. The coating may be applied using a thermal spray process, such as HVOF.

Abstract: A bearing system includes a sleeve bearing supported on a shaft and a gear supported on the sleeve bearing. The shaft has an outer diameter shaft surface, the sleeve bearing has an inner diameter bearing surface and an outer diameter bearing surface, and the gear has a gear bore surface. At least one of the outer diameter shaft surface, the inner diameter bearing surface, the outer diameter bearing surface, and the gear bore surface includes an isotropic surface finish and a hard thin film over the isotropic surface finish. During a break-in period of operation of the bearing system, the hard thin film over the isotropic surface finish breaks in a counter surface of the bearing system to extend a hydrodynamic lubrication period of operation of the bearing system.

Abstract: A slurry pump component is disclosed. The slurry pump component may have a base member fabricated from white iron, and a cladding surface made of a wear resistant material disposed in a tool steel matrix on the base member. The wear resistant material may have a melting point of greater than about 3000° C.

Abstract: A slurry pump component includes a base member with a cladding surface. The cladding surface includes a brazing alloy inner layer, a ductile intermediate layer and a wear resistant outer layer.

Abstract: A remanufactured planet carrier is disclosed having a first plate and a second plate spaced apart from and oriented generally parallel to the first plate. Supports join and support the first and second plates. The remanufactured planet carrier further has a plurality of first pin bores in the first plate and a plurality of second pin bores in the second plate. The first pin bores are parallel and generally aligned with the second pin bores. A cylindrical member extends from a central axis of the second plate away from the first plate with a shaft bore formed within the cylindrical member. The first and second pin bores and the shaft bore each have a surface layer with a hardness of at least about 180 BHN and a strength of at least about 500 MPa.

Abstract: A method and system for processing a bearing component to extend its useful life include using the component in the bearing assembly for a portion of its initial useful life and then removing the component from the bearing assembly. The surface of the removed component is subjected to isotropic finishing, after which a protective wear coating is applied to the surface of the component. Once processed, the used bearing component is reinstalled for use.

Abstract: A power rail includes an aluminum body and a wear coating including stainless steel. The power rail may also include a break-in coating having a lower hardness than the wear coating.

Abstract: A used component, such as an engine block or engine head, has at least one dimension that does not match a dimensional specification for the component. A thermal spray coating of FeAlSiC is applied to build up the dimension. The excess coating is milled off so that the body and coating have a second shape that matches the dimensional specification for the component. The coating has an ordered DO3 crystal structure with a stable aluminum oxide scale that produces oxidation resistance at about 700° C.

Abstract: In one aspect, the present disclosure is directed to a method of making a coated article. The method may include forming a sacrificial substrate in a predetermined shape corresponding with the shape of a final substrate. The method may also include applying a thermal spray coating to the sacrificial substrate. In addition, the method may include separating the thermal spray coating from the sacrificial substrate to obtain a formed sheet of coating material and affixing the formed sheet of coating material to a surface of the final substrate using an adhesive.

Abstract: A power rail includes an aluminum body and a wear coating including stainless steel. The power rail may also include a break-in coating having a lower hardness than the wear coating.

Abstract: A method for coating a component of a track roller frame track tensioning and recoil system is disclosed. The method includes irradiating a surface of the component with a continuous laser to heat the component's surface. The method also includes coating the surface of the component with a thermal spray coating after irradiating.

Abstract: A method of forming a composite overlay compound on a substrate includes forming a mixture including at least one component from a first group of component materials including titanium, chrome, tungsten, vanadium, niobium, and molybdenum. The mixture also includes at least one component from a second group of component materials including carbon and boron, and the mixture further includes at least one component from a third group of component materials including silicon, nickel, and manganese. The mixture of selected component materials is then applied to a substrate material to form an overlay compound on the substrate material. The overlay compound is fused to the substrate to form a metallurgical bond between the substrate material and the overlay compound.

Abstract: In one aspect, the present disclosure is directed to a method of making a coated article. The method may include forming a sacrificial substrate in a predetermined shape corresponding with the shape of a final substrate. The method may also include applying a thermal spray coating to the sacrificial substrate. In addition, the method may include separating the thermal spray coating from the sacrificial substrate to obtain a formed sheet of coating material and affixing the formed sheet of coating material to a surface of the final substrate using an adhesive.

Abstract: A method for coating an element is disclosed. The method includes irradiating a surface of the element with a continuous laser to heat the element. The method also includes coating the surface of the element with a thermal spray coating after irradiating.

Abstract: A target material for thermal spraying may include chromium and at least one of about 0.5-12% by weight of aluminum and about 2-15% by weight of manganese.

Abstract: A method for coating a combustion chamber defining component is disclosed. The method includes applying a thermally conductive layer to a surface of the combustion chamber defining component, the thermally conductive layer having a thermal conductivity greater than the combustion chamber defining component.

Abstract: A bushing includes an interior surface, an exterior surface, a first end, and a second end. An end face forms at least part of each of the first end and the second end. At least one of the exterior surface and the end face includes a sealing surface formed at least in part of a coating including a material having a hardness level greater than about 1200 Knoop. The sealing surface has a thickness greater than about 35 microns and an average roughness (Ra) less than about 0.25 micron. In one embodiment, the bushing may be used on an endless track for a track-type work machine.