Abstract: A metal or alloy powder is cold sprayed onto a turbine engine component to form a bond coat. The bond coat is shot peened with particles at a sufficient velocity to compact and smooth the bond coat surface. The smooth surface promotes the formation of a stable and adhered alumina TGO layer. According to another embodiment, the bond coat is instead cold sprayed with particles at a velocity that is sufficient for the particles to compact and smooth the bond coat, and that is insufficient for the particles to bond with the bond coat. For both embodiments, a heat treatment process under controlled atmosphere may be necessary to promote bonding between bond coat and substrate and as a pre-oxidation step to form the TGO layer.

Abstract: A plurality of powders is admixed to form a substantially homogenous powder mixture comprising each of the alloy elements. At least one of the powders consists essentially of a substantially pure elemental metal. The substantially homogenous powder mixture is cold gas-dynamic sprayed on the substrate to form a coating of the alloy elements. The coating is then heated until the alloy elements inter-diffuse and form the alloy. In an exemplary embodiment, the substantially homogenous powder mixture includes stoichiometric amounts of each of the alloy elements, and each of the powders consists essentially of a substantially pure form of one of the alloy elements.

Abstract: In a method for coating a surface of a turbine component with an environment-resistant aluminide, a coating is formed by cold gas-dynamic spraying a powder material on the turbine component surface, the powder material comprising aluminum, platinum, and at least one additional metal selected from the group consisting of nickel, chromium, hafnium, silicon, yttrium, rhenium, zirconium, cobalt, and tantalum. After forming the coating, at least one thermal diffusion treatment is performed on the turbine component to metallurgically homogenize the coating and thereby form an aluminide coating that includes by weight about 12 to about 30% aluminum, up to about 50% platinum, about 2 to about 25% chromium, about 1 to about 5% hafnium, about 1 to about 5% silicon, about 0.1 to about 1% yttrium, and about 1 to about 3% Zr, and nickel.

Abstract: Platinum containing coatings for corrosion and oxidation protection of a substrate, and platinum electrodeposition methods for coating a substrate. The coating may comprise platinum and at least one supplementary constituent, and the method may involve co-electrodeposition of platinum and the supplementary constituent from a single electrolyte composition. The supplementary constituent may comprise chromium, an oxidation protective reactive element, or an alloy of chromium with a reactive element. Components protected by such coatings are also disclosed.

Abstract: The invention provides an improved method of vibration welding of thermoplastic joints. Such welding is conducted by vibrating two fiber reinforced thermoplastic parts under pressure along their common interface to generate frictional heat to melt and fuse their surfaces together. Fibers from at least one surface penetrate both into the weld and into the other surface. As a result, the welded, fiber reinforced thermoplastic surfaces have increased tensile strength than heretofore achievable. Vibration welds of reinforced thermoplastic surfaces according to this invention achieve a maximum tensile strength as high as about 120% of a weld formed by the unreinforced surfaces of corresponding thermoplastic materials.