Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.

Abstract: A plurality of parts are brazed using an iron/chromium filler metal. The parts are preferably composed of stainless steel. The brazed assembly forms a heat exchanger characterized by good corrosion resistance and low rates of leaching of Ni, which are further improved by a post-brazing conditioning step in an oxygen-containing atmosphere at a temperature of about 150° to 600° C. The preferred brazing filler metal consists essentially of a composition having the formula FeaCrbCocNidMoeWfBgSih wherein the subscripts are in atom percent and total 100%, “b” is about 5 to 20, “c” ranges from 0 to about 30, “d” is 0 to about 20, “e” is 0 to about 5, “f” is 0 to about 5, “g” is about 8 to 15, “h” is about 8 to 15, the balance being incidental impurities of up to about 1 percent by weight of the total composition.

Abstract: A magnetic recording medium having excellent magnetic read/write characteristics and thermal stability characteristics, and a method of manufacturing therefor, and a magnetic read/write apparatus are provided. This magnetic recording medium comprises an orientation control film 3 that controls the orientation of a film provided directly thereabove, a perpendicular magnetic film 5, of which the axis of easy magnetization is generally oriented perpendicular to a substrate, and a protective film 6, that are provided on a non-magnetic substrate 1, wherein the orientation control film 3 is made of a non-magnetic material which contains 33 to 80 at % of Ni and one or more kinds of elements selected from Sc, Y, Ti, Zr, Hf, Nb and Ta.

Abstract: There is provided contact, sliding, fitting-in and ornamental members having a surface treatment structure in which contact resistance is low, and lubricating property and wear resistance are excellent, and capable of being used suitably for any use of contact, sliding, fitting-in or ornament, and a method for manufacturing the same. The surface treatment structure 1 having a plating layer formed on the surface of a substrate 2 comprises a lubrication plating layer 5 made of a plating layer of a metal matrix containing fine particles 4 having lubricating property, and a noble metal plating layer 7 formed on the lubrication plating layer 5. Preferably, an anti-diffusive plating layer 3 made of a metal plating layer is formed under the lubrication plating layer 5, and a joining layer 6 made of a strike plating layer of noble metal is formed between the lubrication plating layer 5 and the noble metal plating layer 7.

Abstract: A process is provided for coating metallic workpieces with a bearing material, wherein the workpiece first receives a hard chromium plating having a pearl or columnar structure type surface. A predominantly silver layer is then galvanically deposited, which fills in and smooths the pearl or columnar structure type surface of the hard chromium plating. Optionally, additional hard chromium platings and predominantly silver-containing layers may be applied, preferably galvanically. The predominantly silver layer may advantageously contain a graphite component.

Abstract: A nickel-gold plating exhibiting high resistance to corrosion, which has a nickel plating layer formed on a base metal (1) and a gold plating layer (3) formed thereon, characterized in that the nickel plating layer (2) has a corrosion potential being brought close to that of the gold plating layer (3) through the reduction of the sulfur content of the nickel plating layer; or which has a first nickel plating layer (6) formed on a base metal, a second nickel plating layer (7) formed on the first nickel plating layer and a gold plating layer formed thereon, characterized in that the first nickel plating layer has a corrosion potential nobler (higher) than that of the second nickel plating layer.

Abstract: An R-T-B magnet (R is at least one kind of rare-earth elements including Y, and T is Fe or Fe and Co) has an electrolytic copper-plating film where the ratio [I(200)/I(111)] of the X-ray diffraction peak intensity I(200) from the (200) plane to the X-ray diffraction peak intensity I(111) from the (111) plane is 0.1-0.45 in the X-ray diffraction by CuKal rays. This electrolytic copper-plating film is formed by an electrolytic copper-plating method using an electrolytic copper-plating solution which contains 20-150 g/L of copper sulphate and 30-250 g/L of chelating agent and contains no agent for reducing copper ions and has a pH adjusted to 10.5-13.5.

Abstract: Enhancing wear and corrosion resistance of an industrial component by depositing a Ni-based alloy coating having a thickness of at least about 50 microns onto a surface of the industrial component by high velocity oxyfuel propulsion of a Ni-based alloy powder containing a) Cr, b) from about 15 to about 25 wt % Mo, c) no more than about 1 wt % Fe, and d) no more than about 1 wt % elements having an atomic number greater than 42. A Ni-based alloy powder for HVOF deposition containing a) Cr, b) from about 15 to about 25 wt % Mo, c) no more than about 1 wt % Fe, and d) no more than about 1 wt % elements having an atomic number greater than 42. A Ni-based coating on an industrial component having enhanced corrosion and wear resistance.

Abstract: A coated metallic mesh having a molecular layer thereon comprising: (1) a metallic mesh comprising at least one aperture; (2) a coating disposed on the metallic mesh that at least partially fills at least one aperture so as to form a partially-filled aperture; and (3) a molecular layer comprising at least one molecule having a hydrophilic region and a hydrophobic region, wherein the hydrophilic region at least partially extends into the partially-filled aperture. Also, provided are coated metallic meshes having bilayers and a method of providing a molecular layer to a coated mesh.

Abstract: Reactive foils and their uses are provided as localized heat sources useful, for example, in ignition, joining and propulsion. An improved reactive foil is preferably a freestanding multilayered foil structure made up of alternating layers selected from materials that will react with one another in an exothermic and self-propagating reaction. Upon reacting, this foil supplies highly localized heat energy that may be applied, for example, to joining layers, or directly to bulk materials that are to be joined. This foil heat-source allows rapid bonding to occur at room temperature in virtually any environment (e.g., air, vacuum, water, etc.). If a joining material is used, the foil reaction will supply enough heat to melt the joining materials, which upon cooling will form a strong bond, joining two or more bulk materials.

Abstract: A method for using a novel ternary nickel-gold-phosphorus brazing alloy for joining nickel-based components together and the assembly so formed.

Abstract: Articles for use in a high-temperature, oxidative environment, methods for manufacturing such articles, and a material system for protecting articles in such an environment are provided where, for example, one article comprises a substrate and a protective layer disposed over the substrate, the protective layer comprising at least about 60 atomic percent of a metal selected from the group consisting of platinum (Pt), palladium (Pd), rhodium (Rh), osmium (Os), iridium (Ir), and mixtures thereof.

Abstract: A performance of a perpendicular magnetic recording medium, such as an increase in output or a decrease in noise, is improved by providing a good orientation of a magnetic recording layer in the perpendicular magnetic recording medium and by reducing an amount of an initial growth layer in the magnetic recording layer. The perpendicular magnetic recording medium includes an under layer, a magnetic recording layer, a protective film, and a liquid lubrication layer, which are sequentially provided on a non-magnetic substrate. The under layer contains non-magnetic NiFeCr or a permalloy-based soft magnetic material.

Abstract: The subject of the invention is a layer system for the decorative coating of galvanizable work pieces. In order to have a layer system which meets strict requirements with regard to corrosion resistance and which, at the same time, has a high abrasion resistance and, in addition, provides a high degree of freedom with regard to decorative coloration, the invention proposes a layer system which is formed by galvanic deposition and comprises a base coat consisting of at least one bright layer and one discontinuous chrome layer as well as a cover coat of mechanically resistant materials deposited by the PVD process.

Abstract: Objects of the present invention are to provide a laminated heat resistant alloy plate has a large area, and to provide a manufacturing method therefor. The laminated heat resistant alloy plate according to the present invention is obtained by brazing a Ni alloy plate having plural striae formed thereon at a predetermined interval and a plate which is made of a material the same as or different from that of the Ni alloy plate with a sheet of Ni solder which is amorphous and does not contain organic binder.

Abstract: To provide a plating method, which enables wide industrial use of the redox system electroless plating method having excellent characteristics, and a plating bath precursor which is preferable for the plating method. The plating method comprises a process oxidizing first metal ions of a redox system of a plating bath from a lower oxidation state to a high oxidation state, and second metal ions of said redox system are reduced and deposited onto the surface of an object to be plated, wherein a process is provided in which by supplying the electrical current to the plating bath, the first metal ions are reduced from said lower oxidation state to thereby activate the plating bath. The plating bath precursor is formed stabilizing the plating bath so that reduction and deposition of the second metal ions substantially do not occur in order to improve its storing performance.

Abstract: In the case where holes are defined in BPSG films, respectively, lower electrodes are formed of polysilicon inside the holes, respectively, a nitride film is formed on top of the respective lower electrodes and one of the BPSG films, and the nitride film is subjected to healing oxidation in a wet atmosphere later in order to prevent oxidation of contact plugs and the lower electrodes, nitrogen is diffused into the upper surface of the BPSG film by ion implantation or boron dose in a layer in the vicinity of the surface of the BPSG film is lowered.

Abstract: An object of the present invention is to provide a process for easily producing a magnetic recording medium exhibiting excellent magnetic characteristics. In the present invention, an orientation-determining film is formed on a non-metallic substrate which has undergone texturing, the orientation-determining film is subjected to oxidation or nitridation, and a non-magnetic undercoat film and a magnetic film are formed on the film.

Abstract: A coated superalloy article is prepared by furnishing a nickel-base superalloy article substrate having a rhenium content of not less than about 4.0 percent by weight, and thereafter depositing an aluminum-containing coating onto a surface of the article substrate. The aluminum-containing coating includes an additive zone having an average aluminum content of not greater than about 27 percent by weight, and a diffusion zone of interdiffusion with the article substrate. A ratio of a thickness of the additive zone to a thickness of the diffusion zone is not greater than about 3:1, and is preferably about 1:1.

Abstract: A method of forming an environmental resistant thermal barrier coating on a copper alloy is disclosed. The steps include cleansing a surface of a copper alloy, depositing a bond coat on the cleansed surface of the copper alloy, depositing a NiAl top coat on the bond coat and consolidating the bond coat and the NiAl top coat to form the thermal barrier coating. The bond coat may be a nickel layer or a layer composed of at least one of copper and chromium-copper alloy and either the bond coat or the NiAl top coat or both may be deposited using a low pressure or vacuum plasma spray.

Abstract: Disclosed are a structure of multi-layered clad plates and sheets for corrosion resistance and a fabricating method thereof. Provided are clad plates and sheets for corrosion resistance in which Ni, Co, Ti, Nb, V, and Zr having an excellent corrosion resistance, or an alloy thereof are bonded to cheap Fe, Cu, or an alloy thereof. Chemical compositions of the clad metals and structures of the clad plates and sheets are easily modified with service conditions of the clad plates and sheets. Also, this invention provides a more cost-effective method based on a resistance seam welding process for fabricating the corrosion-resistant clad plates and sheets.

Abstract: Magnetoelectric multilayer composites comprising alternate layers of a bimetal ferrite wherein one of the metals is zinc and a piezoelectric material for facilitating conversion of an electric field into a magnetic field or vice versa. The preferred composites include cobalt, nickel, or lithium zinc ferrite and PZT films which are arranged in a bilayer or in alternating layers, laminated, and sintered at high temperature. The composites are useful in sensors for detection of magnetic fields; sensors for measuring rotation speed, linear speed, or acceleration; read-heads in storage devices by converting bits in magnetic storage devices to electrical signals; magnetoelectric media for storing information; and high frequency devices for electric field control of magnetic devices or magnetic field control of electric devices.

Abstract: A solder coated lid for a package for an electronic device has a lead-free solder layer comprising a Sn—Sb based solder with a liquidus temperature of at least 220 degrees C. provided on at least a region of the lid where the lid is to be joined to a base of a package. The lid can be joined to a base of a package at a low temperature, thereby reducing vaporization of solder components and adhesion thereof to electronic devices within the package.

Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.

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: In a bipolar plate for a fuel cell including a metal substrate and a metallic coating formed on at least part of a surface of the metal substrate, the durability or the resilience is elevated by suitably selecting a material or a shape of the metal substrate and/or the metallic coating. The material of the metal substrate includes one or more of metals or metal alloys selected from a group consisting of iron, nickel, alloys thereof and stainless steel; and the metallic coating includes a combination of conductive platinum-group metal oxides. The metal substrate may be a thermally oxidized substrate, and the metallic coating may be a conductive oxide. Further, the metallic coating may be a metallic porous element or a metallic porous element having a passivity prevention layer on the surface thereof.

Abstract: An electrically conductive metal element comprises an electrically conductive metal substrate having a layer of Ni—Sn alloy overlying an electrically conductive surface of the substrate and at least one layer of Ag or of Ag containing Sn overlying the Ni—Sn alloy layer. The Ni—Sn alloy(s) has a Sn-content not greater than for Ni3Sn2 for high temperature uses. In a convenient method of forming the element the Sn is applied to one or more layers of Ni in a Ag+Sn mixture and diffused into the Ni layer(s) to form the Ni—Sn alloy layer and at least one layer of Ag or of Ag containing Sn. The element may have a surface layer of SnO2 which can be formed by oxidizing residual Sn which migrates to the outer surface of the at least one layer of Ag containing Sn.

Abstract: Disclosed is a method of electroplating a Ni—Fe—P alloy using a sulfamate solution and, in particular, a method of electroplating a Ni—Fe—P alloy using a plating solution containing nickel sulfamate, iron sulfamate, phosphorous acid, and a buffer agent. The method is advantageous in that a residual stress of a deposited layer is very low and has stable mechanical properties, and excellent thermal and corrosion resistance because the deposited layer is obtained by electroplating the Ni—Fe—P alloy using the sulfamate solution useful in a high rate plating process. Furthermore, the method can be applied to various parent metals such as stainless steel, Inconel and iron alloys, and to various fields because the chemical compositions of the deposited layer are readily controlled by varying the concentration of the plating solution.

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: An article protected by a thermal barrier coating system includes a substrate having a substrate surface, and a thermal barrier coating system overlying the substrate. The thermal barrier coating system has a thermal barrier coating formed of a thermal barrier coating material arranged as a plurality of columnar grains extending generally perpendicular to the substrate surface and having grain surfaces. A sintering inhibitor is within the columnar grains, either uniformly distributed or concentrated at the grain surfaces. The sintering inhibitor is lanthanum oxide, lanthanum chromate, chromium oxide, and/or yttrium chromate, mixtures thereof, mixtures thereof with aluminum oxide, modifications thereof wherein cobalt or manganese is substituted for chromium, precursors thereof, and reaction products thereof.

Abstract: Nickel base superalloy consisting essentially of, in weight %, about 3% to about 12% Cr, up to about 15% Co, up to about 3% Mo, about 3% to about 10% W, up to about 6% Re, about 5% to about 7% Al, up to about 2% Ti, up to about 1% Fe, up to about 2% Nb, about 3% to about 12% Ta, up to about 0.07% C, about 0.030% to about 0.80% Hf, up to about 0.10% Zr, up to about 0.02% B, up to about 0.050% of an element selected from the group consisting of Y and Lanthanide series elements, and balance Ni and incidental impurities with a S concentration preferably of 2 ppm by weight or less. The nickel base superalloy pursuant to the invention possesses improved high temperature oxidation resistance. The nickel base superalloy as a substrate can be coated with an outwardly grown diffusion aluminide bondcoat followed by deposition of a ceramic thermal barrier coating (TBC) on the bondcoat.

Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a &ggr;-Ni+&ggr;′-Ni3Al phase constitution, and a coating including the alloy.

Abstract: A high-temperature strength member comprises a substrate of Ni-based single crystal alloy or a Ni-based unidirectional solidified alloy and a coating of a B-containing alloy having a specified B content formed on the surface thereof by a spraying process or a vapor deposition process.

Abstract: The invention relates to structural components for the boiler zone of power plants or refuse incineration plants, especially tubes or nests of tubes, fin and diaphragm walls, that consist of steel or steel alloys, and is characterized by a continuous closed outer nickel or nickel alloy layer galvanically deposited having a layer thickness of approximately 1 to 5 mm, preferably 1 to 2.5 mm.

Abstract: A nickel base single crystal compliant layer on a ceramic blade has the capability to sustain high stresses and high operating temperature. Layers of nickel and platinum bonded on a single crystal superalloy over a sputtered gold-chromium layer support the high stress levels at elevated temperature without extrusion of the soft platinum or nickel layer and without destruction of an NiO compliant surface. The compliant layers have survived stress and temperature conditions without failure to the ceramic blade and the system can be stressed/heated and unloaded/cooled repeatedly without damage to the ceramic blades. A single crystal nickel base superalloy (i.e., SC180) has high strength properties at elevated temperature. Thin layers of chromium followed by gold are e-beam evaporated on one side of a polished surface of the alloy. Pure nickel is electroplated over this e-beam gold-chromium layer. Platinum is either electroplated or plated electrolessly over the nickel layer.

Abstract: Steel sheet for porcelain enameling capable of realizing excellent enamel adhesion with the steel sheet by direct-on enameling once is provided by using a Ti-added steel sheet; there are also a method for producing the same, as well as a porcelain enamel product and the method for producing the same. A steel sheet for porcelain enameling is produced by providing a Ni—Mo alloy plating film on a Ti-added steel sheet containing 0.01% by weight (wherein, % represents “% by weight” hereinafter) or less of C, 0.5% or less of Mn, 0.04% or less of P, 0.04% or less of S, 0.01 to 0.50% of Ti, and balance Fe accompanied by unavoidable impurities, and by then performing heat treatment thereto to control the content of Ni, Mo, and Fe present in the surface of the steel sheet in a predetermined range, porcelain enamel is applied once and fired.

Abstract: This invention provides a disk which has an in-plane oriented magnetic recording layer on a glass, ceramic, or other nonmetal substrate and a method for making the disc. A thin layer of texturable NiP is sputtered on the substrate. This NiP layer is textured before the magnetic layer is deposited. The disk combines all the advantages of a glass or ceramic substrate along with the advantages of an oriented magnetic medium.

Abstract: A nickel-base superalloy substrate includes a surface region having an integrated aluminum content of from about 18 to about 24 percent by weight and an integrated platinum content of from about 18 to about 45 percent by weight, with the balance components of the substrate. The substrate is preferably a single-crystal advanced superalloy selected for use at high temperatures. The substrate may optionally have a ceramic layer deposited over the platinum-aluminide region, to produce a thermal barrier coating system. The platinum-aluminide region is produced by diffusing platinum into the substrate surface, and thereafter diffusing aluminum into the substrate surface.

Abstract: A method is provided for refurbishing a service operated metallic coating on a substrate alloy, the coating including at least within a coating outer surface at least one oxide chemically grown from at least one coating element, for example Al, and chemically bonded with the coating outer surface as a result of thermal exposure during service operation. Growth of the oxide has depleted at least a portion of the coating element from the coating. The method comprises removing the oxide from the coating outer surface while substantially retaining the metallic coating, thereby exposing in the coating outer surface at least one surface void that had been occupied by the oxide. The retained metallic coating is mechanically worked, substantially without removal of the retained coating, to close the void, providing a treated metallic coating surface over which a refurbishing coating is applied.

Abstract: A surface structure of a metallic body capable of properly maintaining the surface state of a gold layer by preventing diffusion of nickel under conditions of high temperature is provided. In the surface structure of a metallic body of a metal substrate plated with gold, the surface structure includes a nickel layer formed on the surface of the substrate, a barrier layer formed from one or more elements selected from Group 8A of the periodic table formed on the surface of the nickel layer, and a gold layer formed on the surface of the barrier layer.

Abstract: A method for electrodepositing a uniformly thick coating on a metallic mesh is provided, the method comprises the steps of: (1) providing a metallic mesh having a plurality of apertures having at least one dimension greater than nanometer scale sizes; (2) subjecting the metal mesh to a relatively fast deposition of an electrodeposited material so as to substantially uniformly coat said mesh with electrodeposited material; and (3) subjecting the product of the relatively fast deposition step to a relatively slow deposition of an electrodeposited material so as to reduce at least one dimension greater than nanometer scale size to a size of nanometer scale. Also provided are metallic meshes so prepared and spectral filters.

Abstract: The present invention relates to a color cathode ray tube provided with a pressed-type shadow mask. As material for constituting the shadow mask 6, a single plate body made of a composite gradient alloy plate consisting of three layers 6A, 6B, 6C or more in which an alloy element has the concentration gradient which is continuously changed from one surface to the other surface is used. The present invention can realize a pressed mask having a large radius of curvature by self-correcting the thermal deformation such as a doming or the like.

Abstract: A coated article is prepared by furnishing an nickel-base article substrate having a free sulfur content of more than 0 but less than about 1 part per million by weight. A protective layer is formed at a surface of the article substrate. The protective layer includes a platinum aluminide diffusion coating. The protective layer may be substantially yttrium-free, or have a controlled amount of yttrium. A ceramic layer may overlie the protective layer.

Abstract: A low cost aluminide process for moderate temperature applications. A gas turbine engine component is cleaned and coated with a layer of metal, generally aluminum, containing paint. The metal containing paint layer is heated to a first temperature for a first period of time in an air environment to volatilize the solvents in the paint. The metal containing paint layer is heated to a second temperature for a second period of time in an oxygen-free atmosphere to volatilize the solvents in the paint. The now metal layer and component are heated to a third temperature for a third period of time to interdiffuse the metal and the metal of the component. The component and diffusion layer are then cooled to ambient temperature.

Abstract: There is provided an electroless Ni—B plating liquid for forming, a Ni—B alloy film on at least part of the interconnects of an electronic device having an embedded interconnect structure, the electroless Ni—B plating liquid comprising nickel ions, a complexing agent for nickel ions, a reducing agent for nickel ions, and ammonums (NH4+). The electroless Ni—B plating liquid can lower the boron content of the resulting plated film without increasing the plating rate and form a Ni—B alloy film having an FCC crystalline structure.

Abstract: A product (1), in particular a gas-turbine blade (1), has a metallic basic body (2) to which a protective layer (3, 4) for protecting against corrosion is bonded. The protective layer (3, 4) has an inner layer (3) of a first MCrAlY alloy and an outer layer (4) having a second MCrAlY alloy, which is bonded to the inner layer (3). The second MCrAlY alloy is predominantly in the &ggr;-phase and includes 24% to 26% by weight of cobalt. According to a process for producing a protective layer (3, 4), the outer layer (4) is produced by re-melting a region of the inner layer (3) or by deposition of an MCrAlY alloy from a liquid phase.

Abstract: This invention relates to a structure on a bi-color rust-proof barrier layer of a tool head, mainly used to form a surrounding recessed section marked with indication of a size, a model, a trademark and the like on a surface of a tool head (a metallic object) so that the structure on the rust-proof barrier layer painted with the different two colors is provided between the recessed section and the peripheral surface, thereby highlighting the indication marked at the recessed section so as to increase the distinctions of said object from other object.

Abstract: Protective coatings known in the state of art can reveal either good corrosion resistance or good mechanical properties.

Abstract: The surfaces of apparatuses and apparatus parts for chemical plant construction, including, for example, apparatus, container and reactor walls, discharge apparatuses, fittings, pumps, filters, compressors, centrifuges, columns, heat exchangers, dryers, comminuting machines, internals, packings and mixing elements, are coated by a process wherein protuberances having a mean height of from 100 nm to 50 &mgr;m with a mean spacing of from 100 nm to 100 &mgr;m are produced on the surface to be coated and the coating is applied thereon by currentless deposition of a metal layer or of a metal-polymer dispersion layer with the aid of a plating bath which contains a metal electrolyte, a reducing agent and optionally a polymer or polymer blend to be deposited, in dispersed form.

Abstract: The invention relates to a novel thermal spray process for the deposition of coatings with a graded or layered composition and the coated articles produced thereby. More particularly, the invention relates to feeding mixtures of coating materials to a thermal spray device and continuously or intermittently changing the composition of the deposited coatings by changing the thermal spray operating parameters. The continuous or intermittent change in the composition of the coating material during deposition creates a graded or layered coating structure.