Abstract: In a heat-resistant component of a TiAl intermetallic component, in its main body having a friction region subject to friction with other components, a coating discharge-deposited by a consumable electrode covers the friction region.

Abstract: An article having a thermal barrier coating includes a superalloy substrate having a columnar grained ceramic coat formed thereon. The ceramic coat includes a nanolaminate region comprising repeating layers of ceramic material with each layer being less than 500 nm in thickness, with dispersions of metal oxide doping material situated between each of the layers. The ceramic coat further includes a non-doped region having a thickness greater than 500 nm adjacent to the nanolaminate region, the non-doped region including one layer or a plurality of adjacent layers of ceramic material without dispersions of metal oxide doping material situated between each of the layers. In one embodiment, and by way of example only, a bond coat is formed between the substrate and the columnar grained ceramic coat. According to another embodiment, the superalloy substrate forms an adherent alumina scale, and no bond coat is necessary.

Abstract: A method is provided for depositing a hard wear resistant surface onto a porous or non-porous base material of a medical implant. The wear resistant surface of the medical implant device may be formed by a Laser Based Metal Deposition (LBMD) method such as Laser Engineered Net Shaping (LENS). The wear resistant surface may include a blend of multiple different biocompatible materials. Further, functionally graded layers of biocompatible materials may be used to form the wear resistant surface. Usage of a porous material for the base may promote bone ingrowth to allow the implant to fuse strongly with the bone of a host patient. The hard wear resistant surface provides device longevity, particularly when applied to bearing surfaces such as artificial joint bearing surfaces or a dental implant bearing surfaces.

Abstract: A bonding or superfine wire is provided made of copper, with a gold enrichment on the surface thereof, in particular in an amount corresponding to a coating of at most 50 nm. The wire may be bonded by the ball/wedge method, has a copper-colored appearance, and the ball thereof after flame-off has a hardness of less than 95 according to HV0.002. In order to produce the bonding or superfine wire, a copper wire is coated with gold or a copper-gold alloy or gold is introduced into the surface of the copper wire. The wires are bonded to a semiconductor silicon chip.

Abstract: An aluminum alloy article includes an aluminum alloy substrate and a micro-arc oxide film formed on the aluminum alloy substrate. The micro-arc oxide film includes a transition layer gradually infiltrating into the aluminum alloy substrate, a middle dense layer formed on the transition layer, and an outer dense layer formed on the middle dense layer, the outer dense layer having a density larger than that of the middle dense layer.

Abstract: A method of depositing a hard wear resistant surface onto a porous or non-porous base material of a medical implant. The medical implant device formed by a Laser Based Metal Deposition (LBMD) method. The porous material of the base promotes bone ingrowth allowing the implant to fuse strongly with the bone of a host patient. The hard wear resistant surface provides device longevity when applied to bearing surfaces such as artificial joint bearing surface or a dental implant bearing surface.

Abstract: A composite article that can be used as a substrate for coated conductors is disclosed. The composite substrate has at least three layers in which one or more inner layers of Ni—W alloys with 9 at. %-13 at. % W and two outer layers of Ni—W alloys with 3 at. %-9 at. % W. The content of W element gradually decreases from the inner layers to the outer layers. The composite substrate can be prepared using a process of designing and sintering composite ingot, rolling composite ingot and then annealing composite substrate. The composite substrate have a dominant cube texture on the outer layer of the whole substrate which have a weaker magnetism and higher strength than that of a single Ni—5 at. % W alloy substrate.

Abstract: A method of nitriding a metal includes transforming a surface region of a generally nitrogen-free metal into a nitrogen-containing solid solution surface region. A first heating process heats the surface region at a first temperature in the presence of a nitrogen gas partial pressure to form a nitrogen-charged surface portion on the surface region. A second heating process heats the surface region and nitrogen-charged surface portion at a second temperature for a predetermined time to interstitially diffuse nitrogen from the nitrogen-charged surface portion a depth into the surface region. Coincident with the second heating process, an ionized inert or reducing gas removes the nitrogen-charged surface portion. The resulting nitrogen-containing solid solution surface region has a gradual transition in nitrogen concentration.

Abstract: A turbine airfoil having an improved impact and erosion resistance. The airfoil comprises: (a) a base segment having an impact resistant leading edge section proximate to the leading edge comprising a material having having a yield strength of least about 250 ksi and an elongation percentage of about 12% or less; and (b) an erosion resistant coating overlaying the base segment at least in the leading and trailing edge portions of the pressure side, the erosion resistant coating comprising at least one ceramic layer having at least one of the following properties: (1) an erosion value of at least about 200 g. of erodent to cause a thickness loss of about 15-20 microns; (2) an erosion volume loss value (V) of about 1.9 or less as defined by the equation V=H?0.18×E0.75×F?1.65 where H is hardness, E is elastic modulus and F is fracture toughness; and (3) an F value of at least about 1.5 MPa*m1/2.

Abstract: A sliding member comprises an overlay layer that is formed on a copper alloy layer including a second phase composition. The copper alloy layer and the overlay layer have an interface therebetween, and the second phase composition is included in the copper alloy layer except the interface.

Abstract: A transition joint for joining dissimilar metals with the chemical composition of the joint varied in a controlled manner from end to end. The transition joint has a first end of having a chemical composition similar to that of one of the metals to be joined and a second end having a chemical composition similar to that of the other metal with a gradual composition variation between the first and second ends.

Abstract: A high k dielectric film and methods for forming the same are disclosed. The high k material includes two peaks of impurity concentration, particularly nitrogen, such as at a lower interface and upper interface, making the layer particularly suitable for transistor gate dielectric applications. The methods of formation include low temperature processes, particularly CVD using a remote plasma generator and atomic layer deposition using selective incorporation of nitrogen in the cyclic process. Advantageously, nitrogen levels are tailored during the deposition process and temperatures are low enough to avoid interdiffusion and allow maintenance of the desired impurity profile.

Abstract: A method of preparing the surface of a porous metal substrate to receive a membrane. The method does not substantially decrease the average bulk porosity of the metal substrate. A hydrogen separation membrane supported on the porous metal substrate. A cold spray is used to reduce surface variance. Exposure to an ion beam may also be used after application on the cold spray to prepare the surface of the substrate for membrane deposition.

Abstract: Thermal barrier coating systems for use with hot section components of a gas turbine engine include an inner layer overlying a bond coated substrate and a top layer overlying at least a portion of the inner layer. The inner layer includes a thermal barrier material such as yttria-stabilized zirconia. The top layer includes a rare earth aluminate. The thicknesses and microstructures of the layers may be varied depending on the type of component to be coated.

Abstract: An interface device is provided that is insertable at a junction between a first device comprising a first metal and a second device comprising a second metal that is dissimilar to the first metal. The interface device comprises at least one layer comprising an alloy of the first metal and the second metal and having a functionally gradient composition operative to reduce a galvanic effect between the first and second devices.

Abstract: A thermal shield stone for covering the wall of a combustion chamber. The stone includes a hot side which can be exposed to a hot medium and a wall side which is arranged opposite the hot side. A hot side area adjoins the hot side. The wall side adjoins a wall side area. The average particle size in the wall side area is smaller than in the hot side area.

Abstract: A protection part comprising at least two layers including an outer layer and an inner layer has its outer layer made of an aluminum alloy that is reinforced with particles of SiC, the SiC particle content in said alloy lying in the range 15% to 40% by weight, while the inner layer is made of an aluminum alloy that is optionally reinforced with SiC particles, the SiC particle content within the layers increasing from the inner layer towards the outer layer. The part is for use in protecting the leading edge of a blade, in particular a blade or vane in a turbomachine, a helicopter blade, or a propeller blade.

Abstract: An outwardly grown diffusion aluminide bondcoat is formed on a superalloy substrate and has higher concentrations of Al and Pt and lower concentrations of harmful impurities (e.g. Mo, W, Cr, Ta, S, etc.) at an outermost region of the bondcoat than at an innermost region thereof adjacent the substrate. The bondcoat is pretreated prior to deposition of a ceramic thermal insulative layer in a manner that reduces grain boundary ridges on the outermost bondcoat surface without adversely affecting the outermost region thereof, and then is heat treated to thermally grow a stable alpha alumina layer on the bondcoat prior to deposition of a ceramic layer.

Abstract: A refractory metal plate is provided. The plate has a center, a thickness, an edge, a top surface and a bottom surface, and has a crystallographic texture (as characterized by through thickness gradient, banding severity; and variation across the plate, for each of the texture components 100//ND and 111//ND, which is substantially uniform throughout the plate.

Abstract: A 3D multi-layer heat conduction diffusion plate comprises at least one super conduction diffusion plate which is capable of quickly conducting heat energy, has a short cooling time, and can dissipate heat to a surrounding environment. A soft and bendable material capable of transmitting electrical signals or a fiber glass material capable of transmitting signals can be affixed on an upper and lower surface of the aforementioned super conduction diffusion plate. A micro-porous air-permeable ceramic plate having a high thermal conductivity, which is provided with irregularly arranged air-permeable holes can also be affixed to the aforementioned super conduction diffusion plate, so as to allow air to quickly conduct heat energy to the surrounding environment.

Abstract: An improved method is provided for diffusing titanium and nitride into a base material comprising a steel or steel alloy. The composition of the base material generally comprises at least one of the following: more than about 1.95% vanadium, less than about 4.1% chromium, and a presence of cobalt. The method generally includes the steps of providing such a base material; providing a salt bath which includes sodium dioxide and a salt selected from the group consisting of sodium cyanate and potassium cyanate; dispersing metallic titanium formed by electrolysis of a titanium compound in the bath; heating the salt bath to a temperature ranging from about 430° C. to about 670° C.; and soaking the base material in the salt bath for a time of from about 10 minutes to about 24 hours.

Abstract: A metal structure (100) for a contact pad of a semiconductor, which has interconnecting traces of a first copper layer (102). The substrate is protected by an insulating overcoat (104). The first copper layer of first thickness and first crystallite size is selectively exposed by a window (110) in the insulating overcoat. A second copper layer (105) of second thickness covers conformably the exposed first copper layer. The second layer is deposited by an electroless process and consists of a transition zone, adjoining the first layer and having copper crystallites of a second size, and a main zone having crystallites of the first size. The distance a void can migrate from the second layer is smaller than the combined thicknesses of the first and second layers. A nickel layer (106) is on the second copper layer, and a noble metal layer (107) is on the nickel layer.

Abstract: A laminated metal thin plate produced by electrodeposition is composed of a plurality of metal layers provided by at least two kinds of materials different in composition from each other. The laminated metal thin plate includes a first layer excellent in mechanical characteristics and/or chemical resistance and a second layer excellent in electrical characteristics such as electrical conductivity. The first and the second layers are adhered to each other in atomic level directly at their interface, with composition gradient at their interface, or with an adherence buffer layer such as a copper thin film interposed therebetween. The first layer is at first deposited on an electrode substrate. The second layer is deposited on the first layer. Deposition is repeatedly carried out in such a way that the first layers on opposite sides of the second layer are equal in thickness. Finally, the electrode substrate is dissolved and removed.

Abstract: A method for producing a toothed section from a densified sintered material and to such a toothed section, whereas a predensified tooth perform is densified to its final shape at least in one area by means of iteratively acquired data, and the roughness in the area being improved relative to the preform by at least 400%, a surface hardness of at least HB 130 being established.

Abstract: A surface processing method includes the step of increasing a surface hardness of a metal having a nominal composition that includes about 0.21-0.25 wt % carbon, about 2.9-3.3 wt % chromium, about 11-12 wt % nickel, about 13-14 wt % cobalt, about 1.1-1.3 wt % molybdenum, and a balance of iron from a first hardness to a second hardness. For example, the method is used to produce a surface-hardened component that includes a core section having a first hardness between about 51 HRC and 55 HRC and a case section having a second hardness that is greater than the first hardness.

Abstract: An article is presented where the article comprises an alloy having a minor phase dispersed within a matrix phase and a plurality of substantially equiaxed grains. The article further comprises a continuous gradient in grain size from a first grain size at an outer surface of the article to a second grain size at an inner portion of the article, wherein the first grain size is less than the second grain size. Methods for forming the article using high deformation processing are also presented, where the processing includes extruding the feedstock material through a die having a twist channel configured to apply a torsional strain to the feedstock material as it passes through the die to form an extruded billet.

Abstract: A coating process and system for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating system includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.

Abstract: The present invention provides a method for producing a functionally gradient component, such a component having an outer layer of a first material, and an inner core of a second material, there being a gradual change in microstructure across the interface between the two materials, the method having particular application in producing a component formed from two or more aluminium alloys based on the aluminium-silicon (Al—Si) system, the method involving introducing a first molten metal into a mould, and allowing a layer of the first metal to partially solidify against a wall of the mould, decanting the remaining molten portion of the first metal, and introducing a second molten metal into the mould and allowing same to solidify.

Abstract: The invention describes a multi-layered bearing with a supporting metal layer, optionally a bearing metal layer disposed on top of it, an anti-friction layer on top of the latter as well as a wearing layer on top of it. The wearing layer is made from bismuth or a bismuth alloy and the anti-friction layer is made from a copper-bismuth or silver-bismuth alloy or silver.

Abstract: It is to propose an internal member for a plasma treating vessel having excellent resistances to chemical corrosion and plasma erosion under an environment containing a halogen gas and an advantageous method of producing the same, which is a member formed by covering a surface of a substrate with a multilayer composite layer consisting of a metal coating formed as an undercoat, Al2O3 film formed on the undercoat as a middle layer and Y2O3 sprayed coating formed on the middle layer as a top coat.

Abstract: The present invention relates to a method of production of functionally graded materials based on an incremental melting and solidification process. Its operation principle can be described as follows: the materials (metal elements, alloys or ceramics) are melt by the induction heating in the mould, and the continual granules, powders or wire, or even liquid materials, of another metal alloys are fed to the mould. The heating zone is limited to a small part of the mould. The incremental melting and solidification process proceeds from the bottom to the top of the mould by changing the relative position between the mould and the heating apparatus. Usage of this method ensures the obtainment of components with no particular alloy composition, but with a gradual changing of the chemical composition along the casting.

Abstract: A surface treatment element having a textured surface with a plurality of deforming features is pressed against the surface of an article to induce deep and shallow layers of compressive residual stress to form a continuous layer of compressive residual stress extending from the surface to a depth beneath the surface. A method whereby a surface treatment apparatus is pressed into the surface of the apparatus to cause Hertzian loading thereby inducing a deep, high magnitude compressive residual stress below the surface. The deforming features of the surface treatment element cause the lateral displacement of material on the surface of the article thereby cold working the surface and providing a more shallow layer of compressive residual stress at the surface.

Abstract: The invention relates to an alloy consisting of at least three components A, B, C, which form at least a first matrix and a soft phase dispersed therein, with a first surface (5) and a second surface (9) lying opposite it, the proportions of components A, B, C in the alloy being different from one another in the regions of the first (5) and the second surface (8). At least one of the components forms a hard phase and at least one of the other components forms another matrix different from the first matrix, the first matrix being disposed at least in the region of the first surface (5) and the other matrix being disposed at least in the region of the second surface (8), whilst the hard phase is dispersed through both the first and the other matrix.

Abstract: A welded component includes at least one high temperature segment of a high alloy Cr steel with high creep strength and a low temperature segment of a low alloy steel with high toughness and/or a high yield strength which are connected materially to one another via a weld joint. In one such component a gradual transition of chemical, physical and mechanical properties in the joining area is achieved in that between the weld joint and the high temperature segment there are at least two successive clad layers of at least two lower alloy weld metals with a total content of elements which increase the creep strength, such as for example Cr, Mo, W and V, which total content decreases toward the weld joint, and/or an increasing total content of elements which increase the toughness and/or yield strength, such as for example Ni and Mn, which total content increases toward the weld joint.

Abstract: A method is provided for depositing a hard wear resistant surface onto a porous or non-porous base material of a medical implant. The wear resistant surface of the medical implant device may be formed by a Laser Based Metal Deposition (LBMD) method such as Laser Engineered Net Shaping (LENS). The wear resistant surface may include a blend of multiple different biocompatible materials. Further, functionally graded layers of biocompatible materials may be used to form the wear resistant surface. Usage of a porous material for the base may promote bone ingrowth to allow the implant to fuse strongly with the bone of a host patient. The hard wear resistant surface provides device longevity, particularly when applied to bearing surfaces such as artificial joint bearing surfaces or a dental implant bearing surfaces. An antimicrobial material such as silver may be deposited in combination with a metal to form an antimicrobial surface deposit.

Abstract: This invention relates to a method for forming a nickel-based layered structure and a boundary layer containing a solid solution of magnesium and an M-metal on a magnesium alloy substrate. A surface-treated magnesium alloy article made from the above method, and a cleaning solution and a surface treatment solution used in the above method are also disclosed.

Abstract: Methods for fabricating a medical device having at least one porous layer include providing a medical device having at least one alloy and removing at least one component of the alloy to form the porous layer. Although methods may be used to make stent devices with porous layers, any other suitable medical device may be made having one or more porous layers. An alloy may include any suitable combination of metals and sometimes a combination of metal and non-metal. In some embodiments, one or more of the most electrochemically active component(s) of an alloy are removed by the dissolving (or “dealloying”) process, to leave a porous matrix behind. The porous matrix layer may then be infused with one or more therapeutic agents for enhancing treatment of a patient.

Abstract: A fiber-reinforced metal-ceramic composite material having a hot ceramic side and a cool metal side and a graded ceramic-metal zone therebetween, wherein the ceramic content of said composite ranges from 100% at said hot ceramic side to 0% at said cool metal side and the metal content of said composite ranges from 0% at said hot ceramic side to 100% at said cool metal side, and wherein said fiber reinforcement is graded by coefficient of thermal expansion from the hot ceramic side to the cool metal side.

Abstract: An intermetallic composition suitable for use as an environmentally-protective coating on surfaces of components used in hostile thermal environments, including the turbine, combustor and augmentor sections of a gas turbine engine. The coating contains the gamma-prime (Ni3Al) nickel aluminide intermetallic phase and either the beta (NiAl) nickel aluminide intermetallic phase or the gamma solid solution phase. The coating has an average aluminum content of 14 to 30 atomic percent and an average platinum-group metal content of at least 1 to less than 10 atomic percent, the balance of the coating being nickel, incidental impurities, and optionally hafnium.

Abstract: An intermetallic composition suitable for use as an environmentally-protective coating on surfaces of components used in hostile thermal environments, including the turbine, combustor and augmentor sections of a gas turbine engine. The coating contains the gamma-prime (Ni3Al) nickel aluminide intermetallic phase and either the beta (NiAl) nickel aluminide intermetallic phase or the gamma solid solution phase. The coating has an average aluminum content of 14 to 30 atomic percent and an average platinum-group metal content of at least 1 to less than 10 atomic percent, the balance of the coating being nickel, one or more of chromium, silicon, tantalum, and cobalt, optionally one or more of hafnium, yttrium, zirconium, lanthanum, and cerium, and incidental impurities.

Abstract: The present invention is to provide a resin-forming mold having high releasability and permitting a production without increasing production costs. The resin-forming mold can be used to produce a resin-molded product having minute uneven portions on a front face thereof, such as a surface light source device-use light guide for a liquid crystal display, an aspherical micro-lens, micro-Fresnel lens and an optical disk. In the stamper (resin-forming mold) 10 provided with an electroformed layer 11 and a conductive film 12 formed on the electroformed layer 11, the front face layer 12c of the conductive film 12 is formed of aluminum and a back face 12d is formed of nickel as an electroconductive metal. In addition, the constituent composition of the aluminum and the nickel continuously changes from the front face 12c toward the back face 12d. The front face 12c may be formed of aluminum and oxygen. The aluminum may combine with the oxygen to form an oxide of aluminum.

Abstract: A turbine airfoil having an improved impact and erosion resistance. The airfoil comprises: (a) a base segment having an impact resistant leading edge section proximate to the leading edge comprising a material having having a yield strength of least about 250 ksi and an elongation percentage of about 12% or less; and (b) an erosion resistant coating overlaying the base segment at least in the leading and trailing edge portions of the pressure side, the erosion resistant coating comprising at least one ceramic layer having at least one of the following properties: (1) an erosion value of at least about 200 g. of erodent to cause a thickness loss of about 15–20 microns; (2) an erosion volume loss value (V) of about 1.9 or less as defined by the equation V=H?0.18×E0.75×F?1.65 where H is hardness, E is elastic modulus and F is fracture toughness; and (3) an F value of at least about 1.5 MPa*m1/2.

Abstract: A composite comprises a chemical, mechanical and/or optical protective and/or diffusion barrier layer disposed on a metal or plastic substrate. The layer consists of an organic layer matrix with metal-containing particles dispersed therein, the metal-containing organic layer being plasma-polymerized starting from at least one hydrocarbon which can be substituted and one metal-containing component. The protective and/or diffusion barrier layer is used in a thickness (d) in the submicron range and contains metal particles finely dispersed therein, that have a grain size that lies below 50% of the layer thickness (d). The organic layer matrix is deposited by plasma polymerization from a process gas that comprises at least one hydrocarbon that can also be substituted and one metal-containing component and/or an inorganic gas in a reactor that can be evacuated.

Abstract: The present invention relates to an overlay coating which has improved strength properties. The overlay coating comprises a deposited layer of MCrAlY material containing discrete nitride particles therein. The nitride particles are present in a volume fraction in the range of 0.1% to 15.0% and have a particle size in the range of from 0.1 microns to 10.0 microns. The coating may also have oxide particles dispersed therein.

Abstract: Discloses is a metal-based resistance heat-generation element. The element comprises a core made of a platinum group metal or refractory metal, and a coating film formed on the core. The coating film has at least two layers including a core-side inner layer of a Re—Cr based ? (sigma) phase and a surface-side outermost layer of an aluminide or silicide. Alternatively, the element may comprise a core made of an alloy containing a platinum group metal or refractory metal and Re and Cr diffused therein, and a coating film formed on the core. The coating film has at least one layer including an aluminide or silicide layer.

Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.

Abstract: A gas turbine component consists of a superalloy base material with a single crystal structure and a protective MCrAlY-coating (6). The MCrAlY-coating (6) has a g/g? single crystal structure, which is epitaxial with the base material. It has be determined the critical factors for the successful epitaxial and crack-free growth of the MCrAlY-coating (6).

Abstract: A blade with improved sharpness and durability is disclosed. The blade includes a base plate having an edge and a coating layer for coating the edge. The coating layer is formed of a material handling metal, and a tip of the coating layer is sharpened. It is preferred that an angle (Ba) between two tapered surfaces be between 15 to 45 degrees.

Abstract: A new article of manufacture, for example a faucet or other article of hardware, has a specified decorative color, and is resistant to corrosion, abrasion and attack by chemicals. The article includes a substrate, one or more corrosion resistant layers applied to the substrate, a thin transition layer having a composition that varies systematically from a first composition to a second composition and in which the first composition has, at least in part, the function of corrosion protection, and in which the second composition determines the visible color or that portion of the substrate to which the transition layer is applied.

Abstract: Composite wear component produced by casting and consisting of a metal matrix whose working face or faces includes inserts which have a very high wear resistance, characterized in that the inserts consist of a ceramic pad, this ceramic pad consisting of a homogeneous solid solution of 20 to 80% of Al2O3 and 80 to 20% of ZrO2, the percentages being expressed by weights of the constituents, and the pad then being impregnated with a liquid metal during the casting.