Abstract: Method of depositing an Fe.sub.x O comprising coating onto a light metal substrate by use of wire-arc thermal spraying that propels atomized droplets by use of atomizing gases, comprising: preparing at least one surface of the light metal substrate to present an exposed essentially non-oxidized substrate surface; and thermally spraying melted droplets of a steel feedstock wire onto the prepared surface by use of propellant gases to deposit a composite coating, the gases being controlled as to content to regulate the exposure of the droplets to oxygen so that Fe.sub.x O is substantially the only iron oxide formed during spraying, x being 0.5-1.5.

Abstract: A method for coating the internal cylinder bores of a cast aluminum engine block comprising the steps of casting an engine block of aluminum alloy, thermally spraying a wear-resistant coating onto cylinder walls in the engine block by melting the tip of a rotating iron-based alloy rod with a plasma torch within cylinders in the engine block, and honing the cylinder walls to a chosen size.

Abstract: A method of making and the resulting product for a disk brake rotor with a self-lubricating, thermally conductive coating thereon that enhances the friction wear life of a disk brake assembly within which it is used, comprising: (a) controllably toughening at least the outside braking surfaces of a lightweight metal disk brake rotor, said roughening being carried out to promote mechanical adhesion of coatings applied thereover; (b) thermally spraying one or more coatings onto the roughened outside braking surface, the exposed coating being electric arc sprayed using a codeposit of iron-based material and powdered graphite to form an iron matrix composite coating; and (c) surface heat treating essentially the exposed coating to dissolve and precipitate graphite and form a simulated cast iron and also to densify the coating and remove residual stresses resulting from deposition.

Abstract: A method of thermally spraying a solid lubricant (i.e. graphite or BN) impregnated metal matrix onto a metal target, using the steps of: (a) creating a flame or arc into which a consummable strand is fed, the strand being constituted as a hollow sheath of metal and a core therein comprising essentially solid lubricant powder particles, the flame or arc melting the metal of such strand; (b) applying a pressurized jet of atomizing gas to the melt and included graphite particles to project a spray of molten heavy metal and graphite particles generally homogeneously distributed throughout such spray, said graphite being protected against ablation during transit from the flame or arc to the target; and (c) surface heat treating essentially only the deposit to precipitate additional graphite while densifying the metal and controlling microstructure.

Abstract: A method of the thermally spraying a solid lubricant (i.e. graphite or BN) impregnated metal matrix onto a metal target, using the steps of: (a) creating a flame or arc into which a consummable strand is fed, the strand being constituted as a hollow sheath of metal and a core therein comprising essentially solid lubricant powder particles, the flame or arc melting the metal of such strand; (b) applying a pressurized jet of atomizing gas to the melt and included graphite particles to project a spray of molten heavy metal and graphite particles generally homogeneously distributed throughout such spray, said graphite being protected against ablation during transit from the flame or arc to the target; and (c) surface heat treating essentially only the deposit to precipitate additional graphite while densifying the metal and controlling microstructure.

Abstract: This invention is directed to a process for the cryogenic lift-off of metal/resist material from a surface of a substrate.