Abstract: Disclosed herein is a method comprising mixing a carrier liquid with particles and/or with a particle precursor to form a suspension or solution respectively; where the particles comprise a metal oxide; and where the particle precursor comprises a metal salt; injecting the suspension or solution through a plasma flame; and depositing the particles and/or the particle precursor onto a substrate to form an first abradable coating; where the first abradable coating comprises a plurality of cracks or voids that are substantially perpendicular to the substrate surface, where the substrate is a hub surface of a gas turbine engine or where the substrate is a cantilever stator.

Abstract: An embodiment of a method includes retaining a first workpiece and a second workpiece selectively on a workpiece fixture disposed within a deposition chamber. The workpiece fixture includes tooling including a first workpiece holder, a second workpiece holder, and a first hollow wall. The first workpiece is separated from the second workpiece using the first hollow wall. Energy is selectively applied and directed within the deposition chamber, from an energy source toward a first crucible, the first crucible including a plurality of walls defining an upper recess contiguous with, and disposed directly above a first lower recess, at least the upper recess open to an interior of the deposition chamber. During the step of selectively applying and directing energy, a gas valve is controlled to maintain a partial vacuum in the deposition chamber of greater than 2 Pa to control a size and overlap of at least one coating zone formed around each of the at least one workpiece.

Abstract: A method includes forming a multi-layered ceramic barrier coating under a chamber pressure of greater than 1 Pascals. In the method, low- and high-dopant ceramic materials are evaporated using input evaporating energies that fall, respectively, above and below a threshold for depositing the materials in a columnar microstructure (low-dopant) and in a branched columnar microstructure (high-dopant).

Abstract: A thermal barrier coating is applied to a turbine engine component having a substrate. The thermal barrier coating has a first layer which has a strain tolerant columnar microstructure at an interface with the substrate for spallation resistance and a second layer which is porous conduction and radiation thermally resistant at an outer surface of the thermal barrier coating.

Abstract: A system for measuring a temperature of a rotating workpiece comprises a deposition chamber, a crucible within the deposition chamber, an energy source, a drive system, a temperature sensor, first and second sensor wires, a dynamic electrical connection, and a control system. The crucible is configured to hold a deposition feedstock material. The energy source is configured to evaporate the deposition feedstock material. The drive system is configured to rotate the workpiece such that the evaporated deposition feedstock material can impinge the rotating workpiece. The temperature sensor is configured to sense the temperature of the rotating workpiece. The first and second sensor wires are electrically connected to the temperature sensor. The dynamic electrical connection is configured to electrically communicate the signal indicative of the sensed temperature from the rotatable workpiece holder to the stationary portion.

Abstract: An electron beam vapor deposition process for depositing coatings includes placing a source coating material in a crucible of a vapor deposition apparatus; energizing the source coating with an electron beam raster pattern that delivers a controlled power density to the material in the crucible forming a vapor cloud from the source coating material; and depositing the source coating material onto a surface of a work piece.

Abstract: A cylindrical, internally-threaded part such as a nut or standoff that can be clinched into very-thin, sheet-metal panel even if the receiving hole is blind. The part has no integrally-formed displacer. The part is installed in an annular, blind hole by cold deforming and pushing material of the panel with a special installation tool into one or more recesses of the part. The tool has an annular cavity for receiving the fastener, an annular displacer surrounding the outer diameter of the annular cavity, and a center punch surrounded by the inner diameter of the cavity. One recess of the part may comprise an undercut in the outer periphery while another recess may comprise the groove of the internal threads. With a single stroke of the tool, panel material is simultaneously pushed into the undercut by the displacer and into the threads by the center punch to attach the part to the panel by clinching.

Abstract: A coating system for coating a part (10), such as a turbine blade or vane, has a mask (14) positioned adjacent to a first portion (16) of the part (10) to be coated and a mechanism (30) for moving the mask (14) relative to the part (10). The mechanism (30) may be a gear mechanism or a magnetic mechanism.

Abstract: The present invention relates to headed push-in fasteners of the type produced by Penn Engineering & Manufacturing Corp. known as TackPins and TackScrews. More specifically it relates to a Tack Pin or a Tack Screw with a Belleville head that provides the functionality of a Bellville washer without needing a separate part. When installed, the compression of the Bellville shaped head will cause a permanent loading to be applied under the head of the fastener, essentially creating a clamping force to the members being attached.

Abstract: A coating system for coating a part (10), such as a turbine blade or vane, has a mask (14) positioned adjacent to a first portion (16) of the part (10) to be coated and a mechanism (30) for moving the mask (14) relative to the part (10). The mechanism (30) may be a gear mechanism or a magnetic mechanism.

Abstract: A fastener with a tapered head that frictionally mates with a tapered hole in a punched sheet. Frictional attachment is achieved with the fastener head remaining flush with the top of the panel. If a second panel of softer material is placed underneath against the backside of the first panel, in the same pressing step clinch features on the shank of the fastener attach to the second panel and attach the two sheets face-to-face. Attachment of the tapered head with the top panel exploits two different attachment phenomena: a locking taper and, depending on the choice of materials such as stainless steel, attachment by galling.

Abstract: An embodiment of an apparatus includes a deposition chamber, a workpiece fixture including a first workpiece holder, and a first crucible. The workpiece holder is configured to retain a first workpiece in the deposition chamber. The first crucible includes a body including at least one wall defining a non-circular upper recess with a base. A first lower recess is formed below the base of the upper recess and configured to retain a first primary coating feedstock therein.

Abstract: An embodiment of an apparatus includes a first crucible in communication with a deposition chamber, an energy source, and a workpiece fixture. The first crucible includes a plurality of walls defining an upper recess and a first lower recess, at least the upper recess open to an interior of the deposition chamber. The energy source is configured to selectively apply and direct energy within the deposition chamber, including toward the first crucible. The workpiece fixture includes tooling and a plurality of workpiece holders configured to retain at least one workpiece selectively within the deposition chamber. The tooling includes at least one wall separating at least a first of the plurality of workpiece holders from a second of the plurality of workpiece holders.

Abstract: A unitary metal clinch fastener comprises a top most head and an inwardly tapered shoulder extending axially downwardly from and located immediately below the head. The shoulder has an outwardly-facing angled surface for deforming material of a metal panel into which the fastener is installed. An outwardly-flared shank is located below the shoulder. The shank has an upwardly-facing outer surface adapted to engage an edge of an installation hole in the panel. A neck of reduced diameter is located at a junction of the shank and the shoulder and is adapted to engage the edge of the installation hole to attach the fastener to the panel. The panel installation hole is centered in a conical recessed section of the panel and is convergently-angled downwardly with the edge of the hole abutting the upwardly-facing surface of the shank.

Abstract: An article includes a substrate and a multi-layered ceramic barrier coating on a substrate. The coating includes, from the substrate outward, a first layer of a low-dopant ceramic material and a second layer high-dopant ceramic material. The first layer has a columnar microstructure and the second layer has a branched columnar microstructure.

Abstract: A method includes forming a multi-layered ceramic barrier coating under a chamber pressure of greater than 1 Pascals. In the method, low- and high-dopant ceramic materials are evaporated using input evaporating energies that fall, respectively, above and below a threshold for depositing the materials in a columnar microstructure (low-dopant) and in a branched columnar microstructure (high-dopant).

Abstract: An abradable coating for application to a gas turbine engine part is formed from a titanium aluminide alloy, a filler material, and porosity. The coating may be applied to a part such as a casing made from a titanium alloy.

Abstract: A coated component with a coating applied by Electron Beam Physical Vapor Deposition (EB-PVD) includes at least one Non Line of Sight (NLOS) area and at least one Line of Sight (LOS) area, a coating on the workpiece defines a ratio greater than about 10% NLOS/LOS.