Abstract: Abradable coatings are provided. The coatings comprise SrTiO in combination with a ceramic, such as ytrria stabilized zirconia, or SrTiO in combination with an MCrAlX, such as NiCoCrAlY. The abradable coatings are suitable for use in high temperature environments found in gas turbine engines. Also provided are metal articles coated with such coatings, and abradable assemblies.

Abstract: Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

Abstract: Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

Abstract: Abradable coatings are provided. The coatings comprise SrTiO in combination with a ceramic, such as ytrria stabilized zirconia, or SrTiO in combination with an MCrAlX, such as NiCoCrAlY. The abradable coatings are suitable for use in high temperature environments found in gas turbine engines. Also provided are metal articles coated with such coatings, and abradable assemblies.

Abstract: Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

Abstract: Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

Abstract: Thin films or coatings having a thickness of about 100 nanometers or larger are made of nanostructured particles which have a particle size less than 100 nm (i.e. 0.1 micron) by thermally spraying a solution of a liquid coating precursor feedstock onto a substrate to form the film or coating. By thermal spraying with different precursor feedstock solutions, coatings can be made with more than one layer. Also, by varying the composition of the precursor feedstock during spraying, a fine composition gradient coating can be formed which is made up of the same small nanoparticle size particles of less than, 100 nm. Many combinations of materials can be co-deposited and by applying an external energy source either during the coating process or during post deposition, the resulting coating can be modified.

Abstract: Thin films or coatings having a thickness of about 100 nanometers or larger are made of nanostructured particles which have a particle size less than 100 nm (i.e. 0.1 micron) by thermally spraying a solution of a liquid coating precursor feedstock onto a substrate to form the film or coating. By thermal spraying with different precursor feedstock solutions, coatings can be made with more than one layer. Also, by varying the composition of the precursor feedstock during spraying, a fine composition gradient coating can be formed which is made up of the same small nanoparticle size particles of less than 100 nm. Many combinations of materials can be co-deposited and by applying an external energy source either during the coating process or during post deposition, the resulting coating can be modified.

Abstract: A method of making an electrochemical cell, and an electrode stack made thereby. The method includes fabrication of a coating onto selected areas of the ends of the stack by a thermal spray coating process in which the coating is applied to one of the electrodes in the stack without the coating contacting the alternate edges of the other electrode in the stack. Suitable conductive strips, compatible with the substrate materials that make up the electrodes of the cell, can be attached to the thermally sprayed coating layers, or can be embedded into the sprayed materials as they are applied to the electrode stack.

Abstract: A shroud which has an inner surface configured to surround an impeller, with the surface comprising a metallic substrate, and a metallic bond coat overlaying the substrate. A porous spark resistant abradable silver or silver alloy layer overlays the bond coat. The method of forming the porous silver layer is also disclosed.

Abstract: An elevator safety brake for stopping an elevator car is provided with a brake shoe having a fused sprayed friction coating for contacting an elevator guide rail surface to provide a stopping force. In a preferred embodiment, the coating is obtained by plasma spraying an admixture of 85 weight percent nickel-chromium alloy particles and 15 weight percent tungsten carbide particles on a substrate. The plasma sprayed admixture is fused. The fused sprayed friction surface of the brake exhibits a consistent high friction and low wear suitably accommodating high speed, high load elevators installed in very tall buildings.

Abstract: The present invention relates to a thermal barrier coated article with spallation and delamination inhibiting metallic bond coat. The metallic bond coat contains a reactive element oxide, preferably yttria, which reacts with sulfur, typically migrating from the substrate to the thermal barrier coating, to prevent the sulfur from inducing spallation of the oxide scale at the interface of the thermal barrier coating and the metallic bond coat. This metallic bond coat is preferably multi-layered having a reactive element oxide containing layer sandwiched between two reactive element oxide-free layers.

Abstract: A polymeric skin can be molded by heating a mold surface to a temperature sufficient to melt a casting material and controllably projecting particles of the casting material toward the heated mold surface. Particles of the casting material that impinge on the mold surface melt and adhere to the mold surface. The mold surface is cooled to a temperature at which the casting material solidifies to form a skin. By varying the amount or type of material projected toward the heated mold surface, the method can make multilayer skins, skins from more than one material with a graded transition between materials, multicolor skins, and skim having a controlled, nonuniform thickness.

Abstract: A plasma flame spray gun suitable for being constructed physically smaller than comparable power prior art plasma flame spray guns. The gun includes a nozzle having a tapering portion on the inlet side thereof. A cathode with a flat tip is positioned to at least partially extend into the tapering portion of the nozzle. A gas distribution ring is located around the cathode for creating a vortex around the cathode tip. This causes the arc formed between the tip and the nozzle to have a root which spins around the perimeter of the nozzle tip resulting in less wear and, therefore, extended part life.

Abstract: A plasma spray gun system with improved nozzle life. The gun includes a nozzle with a thin annular coolant passage and having a dimension optimized for nozzle life. The system also includes a deionizer to remove ions from the cooling fluid and a dissolved gas remover which also improves nozzle life. In addition, the coolant is treated to remove ions which extends nozzle life even more. Further cooling fluid treatment for even further nozzle life includes dissolved gas removal and heat removal.