Abstract: There is provided a film forming method capable of enhancing adhesion efficiency of a metal powder by use of a low-pressure compressed gas even in the case of spraying the metal powder remaining in a solid-phase state to a substrate, to form a film, the method being a film forming method of spraying a metal powder p in a solid-phase state to a surface 11a of a substrate 11 along with a compressed gas, to form a film 12 of the metal powder p on the surface 11a of the substrate 11, wherein a powder, which at least contains a powder for film formation having an apparent density of 1.4 to 2.0 g/cm3 and an average grain size of not larger than 25 ?m, is used as the metal powder p.

Abstract: A metallized aluminum substrate for mounting a semiconductor device such as LD or LED is provided and a metallized aluminum nitride substrate having excellent dimensional accuracy and high bonding strength of a wiring pattern. An intermediate material substrate is provided, comprising a sintered aluminum nitride substrate having on its surface a wiring pattern constituted of a conductor layer composed of a composition containing at least high-melting point metal powder, aluminum nitride powder and a sintering auxiliary agent for aluminum nitride is prepared. Then, the intermediate material substrate is fired while the sintered aluminum nitride obtained by sintering using a sintering auxiliary agent of the same kind as that of the sintering auxiliary agent contained in the composition is placed so as to be brought into contact with the conductor layer on the surface of the intermediate material substrate or so as to be present in the vicinity of the conductor layer.

Abstract: The invention relates to the use of light-colored or transparent particulate semiconductor materials or particulate substrates that are coated with said semiconductor materials as a hardening and/or drying additive and/or for increasing the thermal conductivity of lacquer systems and printing colors.

Abstract: A process for physically bonding two parts to each other is disclosed. In addition, a process for forming electrical connections have a low resistance is disclosed. The process is generally applicable to the joining of two parts each formed from a metal, an alloy, or a combination thereof. The process finds special use in the formation of multi-celled batteries. The process involves placing two parts or electrical conductors in contact with each other and then bonding them to each other using a kinetic spray process and powder particles. In formation of a multi-celled battery the particles are preferably electrically conductive. The process enables for rapid and cost effective formation of a physical connection. In addition, the connection can have an electrical resistance of less than about 0.5 milli Ohms and strength equal or greater than ultrasonic welding.

Abstract: There is provided a plating structure obtained by heat-treating a silver-plated structure obtained by forming a tin-plated layer, an indium-plated layer, or a zinc-plated layer, having a thickness of 0.001 to 0.1 ?m, on a surface of the silver-plated layer formed on a surface of a plating base. There is also provided a coating method for obtaining the plating structure which comprises the step of melting a particle deposit spottedly deposited at 2×10?6 to 8×10?6 g/cm2 such that the spot-deposited particles have gaps therebetween as viewed above and the particles each having an average diameter of 20 to 80 nm do not pile up in a direction perpendicular to the surface of the silver layer to obtain a film.

Abstract: A plain bearing is provided which has an Sn-and-Si-rich layer formed of an Al alloy containing Sn and Si, and a base material which does not contain Sn. The Sn-and-Si-rich layer have the sliding surface having an area ratio of Sn phase grains in a range of 6 to 40% and that of Si phase grains in a range of 5 to 25%.

Abstract: Preservative composition for various materials and method of preserving the same is disclosed. The preservative composition includes at least one silane-containing material and at least one hydrocarbon solvent containing molecules of at least five carbon atoms.

Abstract: A method for applying a seal strip to a surface of a turbine component by accelerating solid particles to a velocity sufficient to cause the solid particles to plastically deform and bond to the surface and each other when impacted on the surface, and impacting the solid particles on the surface so as to cause the solid particles to deform and bond to the surface and each other to form the seal strip on the surface.

Abstract: The present invention provides a method for manufacturing a heat transfer member which method allows peel-off and cracking possibly caused by thermal expansion to be inhibited. That is, the present invention provides a method for manufacturing a heat transfer member 10, the method at least including a step of forming metal powder into a coating film 12 on a surface of a base material 11 by spraying the metal powder in a solid state onto the surface of the base material 11 together with compressed gas. In the film forming step, a spraying pressure at which the metal powder is sprayed onto the surface of the base material 11 is set so that the coating film 12 has a porous structure.

Abstract: A method for in-situ treatment of a metallic surface utilizing a nanoparticle dispersion to increase at least one of (i) the critical heat flux. (ii) the boiling heat transfer rate, or (iii) the corrosion resistance of the metallic surface when in operation without a nanofluid heat transfer liquid, comprising: (1) cleaning the metallic surface: (2) conditioning the metallic surface to enhance nanoparticle binding to the metallic surface by applying a polymeric binding agent; (3) forming at least one thin film layer of nanoparticles on the metallic surface by contacting the nanoparticle dispersion with the metallic surface at a temperature and pressure sufficient to boil the nanoparticle dispersion; and, optionally (4) curing the nanoparticle layer by heating the metallic surface to a temperature higher than the temperature sufficient to boil the nanoparticle dispersion.

Abstract: The present invention provides a powder blend or composite powder that is fed into a kinetic spray device, accelerated towards a substrate or part in order to form a composite solder with thermal and electrical properties better than existing solder. The other advantages of building a solder layer in this manner include a low oxide content to improve subsequent solderability, excellent control of the deposition thickness, excellent control of the deposition chemistry and lastly, high speed of manufacture.

Abstract: A method for producing an arc-erosion resistant coating provides a substrate material with an arc-erosion resistant layer by a cold-gas spraying method. The method can be used for producing an arc-erosion resistant coating in inner regions of vacuum interrupter chambers that are exposed to electric arcs. An exemplary vacuum interrupter chamber with a shield coated inside is disclosed for medium-voltage switchgear.

Abstract: A method of coating a substrate with cryo-milled, nano-grained particles includes forming a face-centered-cubic gamma matrix comprising nickel, cobalt, chromium, tungsten and molybdenum, adding a dispersion strengthening material to the gamma matrix to form a first mixture, cryo-milling the first mixture to form a second mixture to form a nano-grained structure, and cold spraying the second mixture onto a substrate to form a coating having a nano-grained structure.

Abstract: A rust inhibitor which ensures the simplicity of application typical for a coating process and can demonstrate excellent characteristics similar to those obtained with a metal spraying method. The rust inhibitor is manufactured by admixing zinc and aluminum as fine powders of inorganic metals, which are manufactured with a stamping mill to have a flaky shape, to a modified silicone resin solution. A silane-type silicone resin is used for the modified silicone resin solution. For example, a mixed solution of an organosilane-type silicone resin and an oligomer-type silane coupling agent and the like is used.

Abstract: There is provided a method for applying an improved chromium diffusion coating on an industrial item such as a turbine blade of a gas turbine engine. Chromium and other active metals are combined to form an alloy coating. Active elements include silicon, hafnium, zirconium, yttrium, tantalum, and rhenium. For producing the modified coatings through pack cementation chromium and a master alloy are mixed into a packing along with inert material and a halide activator. The packing surrounds a target in a diffusion box. The metals are then deposited by diffusion onto a target surface by pack cementation methods. The diffusion of the desired metals takes place during a coating thermal cycle. Alternatively, the diffusion can take place using an out-of-pack arrangement. Such modified coatings are utilized as improved performance coatings for environmental resistance applications over the current chromium diffusion coatings.

Abstract: A friction stir welding anvil and method of producing a friction stir welding anvil that precludes diffusion or mechanical bonding of the anvil to the work pieces are provided. The alternatives for producing such an anvil comprise coating the anvil with diffusion barriers such as oxides, nitrides, intermetallics, and/or refractory metals; manufacturing an anvil either completely or partially from the same; or placing a coating of such materials in the form of a thin sheet or a powder between the anvil and the work pieces. The anvil disclosed herein exhibits high strength and hardness even at elevated temperatures, such as those greater than 800° C., so as to prevent the anvil from mechanically or diffusion bonding to the work pieces and so as to minimize, or eliminate altogether, anvil deformation.

Abstract: Process for manufacturing composite metal/ceramic thin films, consisting of: a) preparing a suspension (S) in an organic solvent starting from a substantially homogenous mixture of ceramic reinforcements, metallic particles, a binder, a plasticizer and a dispersant, the metallic particles constituting at least 5% by weight of the suspension; b) tape casting the suspension to form a thin film, and then de-binding said thin film; c) densifying the de-binded thin film in a furnace.

Abstract: An aluminizing composition includes an aluminum-based powder, an inert organic pyrolysable thickener, and a binder selected from the group consisting of colloidal silica, at least one organic resin, and combinations thereof. A method for aluminizing an internal passage of a metal substrate comprises injecting the organic-based aluminizing composition into the internal passage, heat treating the composition under conditions sufficient to remove volatile components from the composition, to cause diffusion of aluminum into surface regions of the internal passage, and to cause decomposition of at least some pyrolysable thickener particles, and burnishing excess material from the internal passage.

Abstract: A method of forming a film is provided. Nanoparticles are deposited on a surface of a substrate using a liquid deposition process. The nanoparticles are linked to each other and to the surface using linker molecules. A coating having a surface energy of less than 70 dyne/cm is deposited over the film to form a coated film. The coated film has an RMS surface roughness of 25 nm to 500 nm, a film coverage of 25% to 60%, a surface energy of less than 70 dyne/cm; and a durability of 10 to 5000 microNewtons. Depending on the particular environment in which the film is to be used, a durability of 10 to 500 microNewtons may be preferred. A film thickness 3 to 100 times the RMS surface roughness of the film is preferred.

Abstract: In one embodiment, a carbide-containing article includes a carbide body with an attached optional superabrasive layer. A braze metal coating is attached to a surface the carbide substrate. The coating primarily is made of particles of a metal having a melting point of less than 1200° C., the particles having a size of less than 0.1 mm. In another embodiment, a process for applying a braze metal coating to a carbide body of a superabrasive or other article includes depositing finely divided particles of a low melting point metal onto the carbide body by spraying the particles and gas onto the body at a velocity that is between 500 km/sec and 2 km/sec, with volumetric delivery of the particles being less than 50 grams per minute.

Abstract: Disclosed is a method for producing a transparent conductive film comprising a coating step for coating a coating solution containing metal nanoparticles on a substrate to form a coated layer, a drying step for drying the coated layer and a baking step for baking the coated layer to obtain a transparent conductive film, wherein a metal in the metal nanoparticles is oxidized to a metal oxide during at least one of the coating step, the drying step and the baking step. According to this method, a transparent conductive film having a low specific resistance and a high light transmittance can be produced by coating.

Abstract: The present invention thus provides an improved method for coating turbine engine components. The method utilizes a cold high velocity gas spray technique to coat turbine blades, compressor blades, impellers, blisks, and other turbine engine components. These methods can be used to coat a variety of surfaces thereon, thus improving the overall durability, reliability and performance of the turbine engine itself. The method includes the deposition of powders of alloys of nickel and aluminum wherein the powders are formed so as to have an amorphous microstructure. Layers of the alloys may be deposited and built up by cold high velocity gas spraying. The coated items displayed improved characteristics such as hardness, strength, and corrosion resistance.

Abstract: The present invention provides methods and materials for use in applying a coating on a surface of a magnesium component. The method includes the steps of: accelerating a coating powder to a velocity of between about 500 to about 1200 meters/second, wherein the coating powder comprises a material selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, and composites; directing the coating powder through a convergent-divergent nozzle onto the surface of the magnesium component; and forming a coating on the surface of the magnesium component so as to substantially cover the surface of the magnesium component. The coating thickness may be between approximately 0.1 to approximately 1.0 mm.

Abstract: The present invention is drawn toward a method of forming conductive paths on a substrate using ink-jet technology. An ink-jettable suspension or solution can be formed containing a conductive particulate having certain desired conductive properties. The suspension can then be ink-jetted onto a substrate such as ceramic, epoxy glass, or other materials in a given pattern using various ink-jet printing technologies and methods. Depending on the chosen conductive particulates, suspension components, and substrate, the printed pattern of conductive particulates may then be heated to further enhance the conductive properties of the particulates through bonding and/or sintering.

Abstract: A process for fabricating a ceramic electroactive transducer of a predetermined shape is disclosed. The process comprises the steps of providing a suitably shaped core having an outer surface, attaching a first conductor to the outer surface of the core, coating an inner conductive electrode on the outer surface of the core such that the inner conductive electrode is in electrical communication with the first conductor, coating a ceramic layer onto the inner electrode, thereafter sintering the ceramic layer, coating an outer electrode onto the sintered ceramic layer to produce an outer electrode that is not in electrical communication with the first conductor, and then poling the sintered ceramic layer across the inner electrode and the outer electrode to produce the ceramic electrode.

Abstract: Methods are disclosed for forming a metal substructure that will subsequently be overcoated with ceramic layers to create a dental restoration. The methods involve the steps of providing a metal powder and applying the metal powder to a die and sintering the metal powder to form a solid structure that may be used as a coping. The application of the metal powder is done in a controlled fashion while minimizing the amount of necessary handwork. These application methods include: (a) alternatingly applying an adhesive and a metal powder to the selected portion of the die surface; and (b) forming the metal powder into a viscous slurry or slip and then dipping the die therein or spraying or pouring the slurry or slip onto the selected portion of the die surface.

Abstract: The present invention relates to a method of forming metallic foams using cold spray processing. The method allows for the formation of metallic foams on existing substrates as a layer. The method includes the steps of providing a substrate for coating of a metallic foam; cold spraying a mixture of metal particles and a foaming agent onto the substrate to form a substrate coated with an unexpanded metallic layer; foam heat treating the substrate coated with an unexpanded metallic layer at a temperature above the decomposition temperature of the foaming agent for a time sufficient to form a heated substrate coated with an expanded metal foam layer; and cooling the heated substrate coated with an expanded metal foam layer to about ambient temperature to form a cooled substrate coated with an expanded metal foam layer. The method of forming metallic foams on substrates finds application in the oil, gas, and chemical industry by being an integral part of casings, pipelines, transfer lines, and other flow lines.

Abstract: Methods for the production of functionally graded material (FGM) are provided. FGM is processed by powder cold spraying ceramic-metal layers, the final shape is pre-pressed by cold isostatic pressing and is then sintered using field activated sintering technique (FAST). The FGM materials can be used for medical applications.

Abstract: The present invention relates to hard coating of ferrous metal substrates using a laser beam with diamond particles in a metal matrix produced from precursor powders of metals which bond to the diamond particles and to the ferrous substrate. The hard coating is particularly useful for white iron castings for pumps (200) used in piping tar sand and water mixtures.

Abstract: A new kinetic spray process is disclosed that enables one to secure a plurality of ceramic elements together quickly without the need for glues or other adhesives. The process finds special utilization in the formation of non-thermal plasma reactors wherein the kinetic spray process can be used to simultaneously secure the ceramic elements together and to form electrical connections between like electrodes in the non-thermal plasma reactor.

Abstract: An environmentally resistant gas turbine engine disk is disclosed. The disk includes a substrate metal having locally enriched surface regions, the locally enriched surface regions comprising alloying elements present in a higher percentage than found in the substrate metal. A method for making the disk and other articles is also disclosed. The method includes furnishing a plurality of powder particle substrates made of a substrate metal, providing a nonmetallic precursor of a metallic coating material, wherein the metallic coating material includes an alloying element that is thermophysically melt incompatible with the substrate metal, contacting the powder particle substrates with the nonmetallic precursor, and chemically reducing the nonmetallic precursor to form coated powder particles comprising the powder particle substrates having a surface-enriched layer of the metallic coating material thereon, wherein the step of chemically reducing is performed without melting the powder particle substrates.

Abstract: A novel coating composition is provided for imparting corrosion and wear resistance to metal substrates. The novel coating composition is thermally applied and comprises an aluminum alloy mixed with a hard, inert matrix. The coating composition has found particular use in providing corrosion and wear resistance to metal seat rails used to secure aircrafts seats to the aircraft frame.

Abstract: A cold gas spraying method and device, whereby the sprayed particles are accelerated in a gas flow. A powder tube and an outer nozzle body together form a Laval nozzle that produces high gas flow velocities. The injection of the sprayed particles occurs in the divergent section of the Laval nozzle.

Abstract: A method for coating and an associated assembly including such a coating are provided. The assembly includes a workpiece defining a weld portion, such as a friction weld joint and a heat affected zone. A coating is disposed on the weld portion to at least partially cover the weld portion, thereby providing enhanced corrosion resistance to the workpiece.

Abstract: The present invention provides a method to coat an article using a plating process, either electroless or electrolytic, whereby nickel is plated on the article using a solution that includes a suspension of powders or containing one or more of the following elements: Ni, Cr, Al, Zr, Hf, Ti, Ta, Si, Ca, Fe, Y and Ga. Optionally, the coating is then heat treated at a temperature above about 1600° F. for an effective amount of time to allow to homogenize the coating by allowing effective interdiffusion between the species. The level of aluminum may be altered to produce a coating of the predominantly ? phase of the NiAl alloy composition. Optionally, a TBC layer is applied over the predominantly ? phase NiAl alloy composition metallic bond coat.

Abstract: The present invention is directed to a process for preparing aluminum and aluminum alloy surfaces in heat exchangers for brazing by depositing thereon a kinetic sprayed brazing composition. The process simultaneously deposits monolith or composite coatings that can include all braze materials and corrosion protection materials used in the brazing of aluminum fins to plates and tubes in a single stage.

Abstract: Disclosed is a fuel tank for a motor vehicle whose inner face is processed with an inorganic coating agent comprising (A) fine particles carrying silver and/or copper and (B) inorganic fine particles, and the tank inhibits oxidation of the fuel such as gasoline or light oil, and further decreases the cluster of gasoline or light oil to make finer the particle size of atomized fuel, thereby improving ignitionability and combustibility, which makes it possible to decrease imperfect combustion and to decrease substantially the consumption of the fuel.

Abstract: A method of maintaining a non-obstructed interior opening in a kinetic spray nozzle is disclosed. The method includes the steps of providing a mixture of particles including first particle population and a second particle population; entraining the mixture of particles into a flow of a gas at a temperature below the melt temperature of the particle populations; and directing the mixture of particles entrained in the flow of gas through a supersonic nozzle to accelerate the first particle population to a velocity sufficient to result in adherence of the first particle population on a substrate positioned opposite the nozzle. The operating conditions of the kinetic spray system are selected such that the second particle population is not accelerated to a velocity sufficient to result in adherence when it impacts the substrate.

Abstract: The invention relates to the technology of applying a coating of powder materials by spraying and can be used for producing a coating of metals; their mechanical mixtures and dielectrics, adding various functional properties to treated surfaces. The proposed method of applying a powder coating comprised as follows: producing a gas-carrier flow, mixing powder with it, accelerating the gas-powder flow in the nozzle, generating its preset profile, further simultaneously generating the second gas-carrier flow, heating it, generating its preset profile and accelerating it in the nozzle, after that superimposing the accelerated gas-powder flow of the preset profile over the gas-carrier flow of the preset profile, and directing the cumulative jet to an article.

Abstract: Algae-resistant roofing granules consisting of one or two coats of a fired semi-ceramic composition having a metallic copper powder which does not significantly affect the color tint strength of the pigment contained in the coatings.

Abstract: A method is for direct application of a brazing flux material to a brazing surface. The method includes the step of applying a brazing filler material to a substrate utilizing a kinetic spray process to form a brazing surface. Following application of the brazing filler material to the substrate brazing flux material can be directly applied to the brazing surface as either a dry powder or a wet slurry. The nature of the brazing surface allows the applied flux material to adhere to the surface without the utilization of additional binders or resin materials.

Abstract: The invention relates to a process for producing a surface layer with embedded inter-metallic phases, which is distinguished by the fact that a layer comprising a metal and a ceramic is applied to a substrate element, that a reaction takes place between the metal and the ceramic of the layer as a result of energy being introduced during the application of the layer or as a result of a subsequent introduction of energy, and as a result the surface layer is produced, with inter-metallic phases being formed.

Abstract: Described herein is a method to fabricate porous thin-film electrodes for fuel cells and fuel cell stacks. Furthermore, the method can be used for all fuel cell electrolyte materials which utilize a continuous electrolyte layer. An electrode layer is deposited on a porous host structure by flowing gas (for example, Argon) from the bottomside of the host structure while simultaneously depositing a conductive material onto the topside of the host structure. By controlling the gas flow rate through the pores, along with the process conditions and deposition rate of the thin-film electrode material, a film of a pre-determined thickness can be formed. Once the porous electrode is formed, a continuous electrolyte thin-film is deposited, followed by a second porous electrode to complete the fuel cell structure.

Abstract: A metallic base material is covered with a coating layer of intermetallic compound, or a plurality of metallic base materials are welded to each other with an intermetallic compound, with reduced energy consumption within a short period of time. First metallic substance 31 in powdery form is piled up on metallic base material 2. Second metallic substance 3 in molten form is delivered onto piling layer 80 of the first substance. Thus, under the control of reaction initiation temperature, coating layer (or building up coating layer) 84 of intermetallic compound having a thickness of hundreds of microns (&mgr;m) to millimeters (mm) is formed on the base material 2 by the self-exothermic reaction between the first substance and the second substance. This method is also useful in the welding of a plurality of metallic base materials to each other with an intermetallic compound. The first substance can be constituted of, for example, Ni, Co or Fe. The second substance can be constituted of, for example, Al or Ti.

Abstract: A method for manufacturing a cover assembly including a transparent window portion and a metallic frame that can be joined to a micro-device package base to form a hermetically sealed micro-device package. A sheet of a transparent material is provided having a window portion defined thereupon, the window portion having finished top and bottom surfaces. A frame-attachment area is prepared on the sheet, the frame-attachment area circumscribing the window portion. A first quantity of powdered metal particles is sprayed onto the prepared frame-attachment area of the sheet using a jet of gas, the gas being at a temperature below the fusing temperature of the metal particles. The jet of gas has a velocity sufficient to cause the metal particles to merge with one another upon impact with the sheet and with one another so as to form an initial continuous metallic coating adhering to the frame-attachment area of the sheet.

Abstract: In accordance with the present invention, there are provided methods for enhancing the color of gemstone(s) by subjecting a combination of a gemstone and at least one finely divided form of a selected treating agent including the element copper to a temperature in the range of about 700° C. up to about 1000° C., for a time period in the range of about 3 hours up to about 600 hours, under conditions suitable to enhance the color of the gemstone, wherein the treating agent consists of a finely divided form of the selected treating agent such as copper metal or copper oxide, and wherein said gemstone is topaz or sapphire and the enhanced color lies in the color spectrum of light yellow to red.

Abstract: Colored roofing granules and methods for their preparations, having decorative metallic appearance and enhanced stability against discoloration of color containing a silica-encapsulated metallic flake or colored lamellar effect pigment distributed in an insolubilized alkali silicate coating.

Abstract: The present invention relates to methods for selectively enhancing corrosion protection of fabricated metal parts. One method of the present invention includes providing a non-galvanized metal sheet to be processed to form the fabricated metal part; selecting a localized region on the non-galvanized metal sheet; roughening the localized region for acceptance of a protective coating; applying a protective coating to localized region; and fabricating the non-galvanized metal sheet into a fabricated metal part. Another method includes providing a galvanized metal sheet; selecting a localized region on the galvanized metal sheet; applying a protective coating to the localized region; and fabricating the galvanized metal sheet into a fabricated metal part. Yet another method includes selecting a localized region on a fabricated metal part; roughening the localized region for acceptance of a protective coating; and applying the protective coating to the localized region.

Abstract: A surface of a nickel-base article such as an internal surface of a gas turbine airfoil is protected with a donor layer of aluminum and at least one other element. To form the protective layer, a donor alloy is contacted to the protected surface of the article, and simultaneously the article and the donor alloy are heated to a coating temperature that is greater than about 0.7 of the absolute solidus temperature of the donor alloy but is such that the donor alloy remains in the form of a condensed phase contacting the protected surface of the article. The donor alloy is thereafter interdiffused into the protected surface of the article.

Abstract: A method for forming a metal-containing layer on a substrate is disclosed. A slurry of the metal is first deposited on the substrate; followed by heating to remove volatile material from the slurry, and to form a layer of the metal. In another embodiment, a slurry of aluminum is deposited over the slurry of the metal, before or after the metal has been heat-treated to some degree. A diffusion heat treatment results in a coating which includes the noble-metal aluminide compound. Related articles are also disclosed.