Abstract: Electrostatic deposition of high performance powdered materials onto gas turbine surfaces. The process also includes post-deposition thermal staging of the deposited powder to provide a durable coating that will satisfy the demands of turbine engine operation. The process envisions application of organic-based powdered materials, glass/ceramic powdered materials and metal-based powdered materials and combinations thereof using electrostatic techniques to components exposed to low temperature operations, such as may be found in the front section of a gas turbine engine or to the exterior portions of an aircraft engine, and metal-containing glass ceramics, glass-ceramic materials, or materials that can be transformed into glass ceramic materials, when applied to components exposed to high temperature operations, such as may be found in the turbine and exhaust sections of a gas turbine engine or the flaps of an aircraft.

Abstract: Electrostatic deposition of high performance powdered materials onto gas turbine surfaces. The process also includes post-deposition thermal staging of the deposited powder to provide a durable coating that will satisfy the demands of turbine engine operation. The process envisions application of organic-based powdered materials, glass/ceramic powdered materials and metal-based powdered materials and combinations thereof using electrostatic techniques to components exposed to low temperature operations, such as may be found in the front section of a gas turbine engine or to the exterior portions of an aircraft engine, and metal-containing glass ceramics, glass-ceramic materials, or materials that can be transformed into glass ceramic materials, when applied to components exposed to high temperature operations, such as may be found in the turbine and exhaust sections of a gas turbine engine or the flaps of an aircraft.

Abstract: A carbon composite construction includes carbon fibers having a controlled level of electrical resistance. The controlled level of electrical resistance is achieved by subjecting the carbon fibers to a predetermined stress level during the stabilization process. The carbon fibers produced by this method are blended with nonconductive fibers to produce the composite construction.

Abstract: A non-destructive method of detecting subsurface defects in thermal barrier coatings applied to gas turbine engine components is provided. In an exemplary embodiment, the method includes positioning a evanescent microwave microscope probe adjacent a turbine component surface coated with a thermal barrier coating, and scanning the thermal barrier coating by moving at least one of the evanescent microwave microscope probe and the component surface in relation to one another in an x-y plane while maintaining a predetermined distance between the probe and the thermal barrier coating constant.

Abstract: A non-destructive method of detecting subsurface defects in thermal barrier coatings applied to gas turbine engine components is provided. In an exemplary embodiment, the method includes positioning a evanescent microwave microscope probe adjacent a turbine component surface coated with a thermal barrier coating, and scanning the thermal barrier coating by moving at least one of the evanescent microwave microscope probe and the component surface in relation to one another in an x-y plane while maintaining a predetermined distance between the probe and the thermal barrier coating constant.

Abstract: Non-spherical particles including a major dimension, for example flakes of material, are positioned with the major dimension oriented generally along an article surface in respect to which the particle is disposed. The particles, disposed in a fluid medium, the viscosity of which can be increased to secure the particles in position, are positioned using a force on the particles. The force includes torque force from a magnetic field, force from flow of the fluid medium, the force of gravity, and the force of surface tension alone or in combination with the force of gravity.

Abstract: A method for the polymerization of metal oxo-hydroxide in solution to form dense contiguous oxide films on small particles suspended in the solution. A standard ethanol-based sol-gel reaction solution is prepared by resulting in a solution containing dissolved metal oxo-hydroxides and phosphates, as well as finely divided suspended metal substrate particles. Intermediate molecular weight alcohols, namely alcohols with three, four, five, six or seven carbon atoms, are added to the reaction solution to increase the boiling point of the reaction. The temperature of the reaction solution is raised to below the boiling point of the solution. Water is added to the reaction solution to initiate the polymerization of the metal oxo-hydroxide. The polymerization reaction, coupled with the phosphates acting a surfactant, coats the metal substrate particles with a dense contiguous coating of metal oxide.

Abstract: Non-spherical particles including a major dimension, for example flakes of material, are positioned with the major dimension oriented generally along an article surface in respect to which the particle is disposed. The particles, disposed in a fluid medium, the viscosity of which can be increased to secure the particles in position, are positioned using a force on the particles. The force includes torque force from a magnetic field, force from flow of the fluid medium, the force of gravity, and the force of surface tension alone or in combination with the force of gravity.

Abstract: Apparatus and method for producing metallic flake having an environmental coating for use in oxidative and corrosive atmospheres. Fluidized bed techniques are utilized to perform a controlled oxidation of metallic particles that include aluminum. The fluidized techniques permit the formation of a thin, outer shell of alumina over the outer surface of the flake. Because the oxidation is controlled so that the selective oxidation produces a thin outer shell, the particle has good reflectance and the metallic core of the particle is unaffected by the oxidizing treatment. Although the techniques of the present invention are effective for producing a reflective surface on aluminum-containing iron alloys while the core particles can be either magnetically soft or hard, the techniques can be used to produce a reflective surface that is corrosion and oxidation resistant on any aluminum containing alloy. Apparatus that facilitates the controlled oxidation is also set forth.

Abstract: A coating is prepared by providing a plurality of metallic flake particles, depositing a surface-protective applied layer on the particle surfaces to form protected particles, and mixing the protected particles with a binder precursor to form a coating mixture. The coating mixture is applied to a substrate. The surface-protective applied layer is preferably silica, which is deposited by a sol-gel process from a tetraethyl orthosilicate solution.