Abstract: A method for deploying an epoxy-based coating on a surface of an article, the method comprising the steps of: (a) providing an article including a metallic surface to be coated, the metallic surface presenting itself as a substrate; (b) preparing a self-sustaining, cloth-like, flexible, non-woven fibrillated PTFE preform with voids therein; (c) conforming the preform to the metallic surface; (d) infiltrating at least some of the voids with an epoxy in an uncured state; and (e) curing the epoxy; whereby an epoxy-based coating is formed on the metallic surface. In some embodiments, the PTFE preform in step (b) is a composite fibrillated PTFE preform comprising PTFE mixed with hard particles. Articles of manufacture are also disclosed having an epoxy-based coating deployed according to the embodiments of the disclosed coating methods.

Abstract: A method of co-forming a metal article comprising forming a powdered metal component from a first powdered metal composition, providing a polymeric foam, coating the polymeric foam with a second powdered metal composition to form a coated polymeric foam, placing the coated polymeric foam in contact with the powdered metal component to form a composite, and heat-treating the composite to volatilize the polymeric foam and to solidify the powdered metal component. The powdered metal composition of the powdered metal component can be the same or different than the powdered metal composition used to coat the polymeric foam. The resulting co-formed metal article can be in a variety of configurations including, but not limited to, metal foam on the inside or outside surfaces of a metal tube and metal foam on one or more faces of a metal plate.

Abstract: A method of co-forming a metal article comprising forming a powdered metal component from a first powdered metal composition, providing a polymeric foam, coating the polymeric foam with a second powdered metal composition to form a coated polymeric foam, placing the coated polymeric foam in contact with the powdered metal component to form a composite, and heat-treating the composite to volatilize the polymeric foam and to solidify the powdered metal component. The powdered metal composition of the powdered metal component can be the same or different than the powdered metal composition used to coat the polymeric foam. The resulting co-formed metal article can be in a variety of configurations including, but not limited to, metal foam on the inside or outside surfaces of a metal tube and metal foam on one or more faces of a metal plate.

Abstract: An article of manufacture having a wear-resistant cylindrical surface is made up of a metallurgically tough base steel with a substantially cylindrical surface, a thin, cylindrical metal sleeve mated to and affixed to the cylindrical surface of the base steel, and a composite metallic coating containing particles having a hardness greater than Rockwell C 70 metallurgically bonded to the surface of the sleeve opposite the base steel/sleeve interface.