Abstract: A protective coating system for metal components includes a superalloy metal substrate, such as a component of a gas turbine. A single layer bond coat is applied to the superalloy metal substrate in a thermal spray process from a homogeneous powder composition having a particle size distribution wherein about 90% of the particles by volume are within a range of about 10 ?m to about 100 ?m. The percentage of particles within any 10 ?m band within the range does not exceed about 20% by volume, and the percentage of particles within any two adjacent 10 ?m bands within the range does not deviate by more than about 8% by volume.

Abstract: In an Al composite material collapsible in the presence of moisture, the external surface of small pieces or powder constructed from a single or a plurality of crystalline grains of Al or an Al alloy is covered with a film of a low melting point metal or alloy selected from the group consisting of In, Sn, combinations of In and Sn, and alloys thereof. The content of the foregoing low melting point metal or alloy ranges from 0.1 to 20% by mass on the basis of the total mass of the composite material. A component member for a film-forming chamber is also provided, which is provided with a water-collapsible Al film on the surface thereof. Film-forming operations are continued over a long period of time using the component member for a film-forming chamber provided with the water-collapsible Al film and then film-forming materials can be recovered from the component member on which the film-forming materials are deposited in a substantial thickness.

Abstract: To provide a thermal spray membrane contact material, contact member and contact part and an apparatus to which they are applied, showing excellent seizure resistance and wear resistance even under high surface pressure/low speed sliding, high speed/high temperature sliding, or high surface pressure/high speed sliding.

Abstract: Disclosed herein is a turbine component comprising a substrate; and a protective structure formed on the substrate, wherein the protective structure comprises an ?-? titanium alloy, a ?-titanium alloy or a near-? titanium alloy. Disclosed herein too is a process for providing a protective structure to a turbine component, comprising affixing a protective structure on a turbine component; wherein the protective structure comprises an ?-? titanium alloy, a near-? titanium alloy or a ?-titanium alloy.

Abstract: To provide a thermal spray membrane contact material, contact member and contact part and an apparatus to which they are applied, showing excellent seizure resistance and wear resistance even under high surface pressure/low speed sliding, high speed/high temperature sliding, or high surface pressure/high speed sliding.

Abstract: Method and arrangement for spray forming an article. The method includes spraying a plurality of metal streams upon a low-heat resistant model and thereby forming a spray formed article. Each of the plurality of metal streams is composed of moltenized droplets, and as between the plurality of metal streams, each is composed of different constituent elements. In the spray form process, conditions of the metal streams are controlled, particularly around the time that the droplets land, to prevent adverse affects such as melting or burning the master model. The spray conditions are controlled in such a manner that the individual metal droplets forming the metal streams remain substantially segregate. The segregated state is maintained through out solidification so that the resulting spray formed article is composed at least partially of psuedo-alloy.

Abstract: The present invention provides a fuel tank or a fuel pipe excellent particularly in the corrosion resistance of the outer surface in a salt damage environment, and is a fuel tank or a fuel pipe excellent in corrosion resistance characterized by: being formed by using a steel sheet or a steel pipe containing Cr of 9.0 to 25.0 mass % as the base material; on the outer surface thereof, having any one or more of welded portions, brazed portions and structurally gapped portions contacting components; and having one or more of metals, whose electrode potential in a 5%-NaCl aqueous solution at 30° C. is ?0.4 V or less relative to a saturated calomel electrode, attached to at least a part or parts of said portion(s) of the outer surface in an electrically conductive manner.

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: A coated article having a high resistance to particle-impact damage has a substrate, and a layered coating overlying the substrate. The layered coating includes a substantially continuous quasicrystalline layer, and a substantially continuous ductile metallic layer in facing contact with the quasicrystalline layer. The coated article is preferably used in applications where it is subjected to particle-impact conditions.

Abstract: Liquid aluminum is sprayed onto an iron article to produce a thin tenacious non-corrodible layer. In one embodiment, an iron article is heated to at least 400° F. or preferably until cherry red. It is sprayed with a fine aluminum mist generated by heating aluminum in a container and then passing a gas under pressure through the container and out through a heat resistant ceramic nozzle. In another embodiment, aluminum is heated to at least 2000° F. in a container to produce a pool of liquid aluminum. Pressure is applied to the container to project the liquid aluminum in the form of a fine mist through a ceramic nozzle onto the iron article. The aluminum mist produces a tenacious aluminum layer on the iron article that is workable, weldable and non-corrodible. The aluminum layer is a permanent part of the iron article and cannot be removed by conventional means, such as buffing with a wire wheel driven by a electric motor.

Abstract: The invention relates to a wear-resistant coating used for bearing surfaces and flanks of piston rings in internal combustion engines. The wear-resistant inventive coating is obtained by mechanically alloying powders which form a metallic matrix with hard material dispersoids and lubricant material dispersoids. The coating is then thermally applied to the workpieces, especially by means of high velocity oxygen fuel spraying (HVOF). The workpieces coated are bearing surfaces and parts of flanks pertaining to piston rings in internal combustion engines.

Abstract: A method applying a thermal barrier coating to a metal substrate, or for repairing a thermal barrier coating previously applied by physical vapor deposition to an underlying aluminide diffusion coating that overlays the metal substrate. The aluminide diffusion coating is treated to make it more receptive to adherence of a plasma spray-applied overlay alloy bond coat layer. An overlay alloy bond coat material is then plasma sprayed on the treated aluminide diffusion coating to form an overlay alloy bond coat layer. A ceramic thermal barrier coating material is plasma sprayed on the overlay alloy bond coat layer to form the thermal barrier coating. In the repair embodiment of this method, the physical vapor deposition-applied thermal barrier coating is initially removed from the underlying aluminide diffusion coating.

Abstract: A component (10) including a substrate material (12) and a wear alloy coating (14) applied to the substrate by a cold spray process. Particles of the wear alloy coating material (16) are directed toward a target surface (18) of the substrate at a velocity sufficiently high for the particles to deform and to adhere to the target surface. The size and/or composition of the particles may be varied during the cold spray process to produce a coating with a varying property across the depth of the coating. Particles of the wear alloy material may be applied by cold spraying along with particles of a second material such as a lubricant or a ceramic material. For Group 5 hard facing materials, the size and distribution of the embedded carbide nodules may be controlled by controlling the selection of the carbide particles being sprayed.

Abstract: One method of the present invention relates to a method for enhancing adhesion of sprayed metal to a ceramic model. The method is comprised of providing the ceramic model having a spray surface, and modifying at least a portion of the spray surface of the ceramic model to enhance adhesion of spray metal to the spray surface.

Abstract: Electromagnetic wave absorbing materials comprising magnetic alloy particles and an insulating matrix are disclosed. The magnetic alloy particles comprise a transition metal such as Fe and/or Co, and further comprise at least one refractory metal such as Ti, V, Cr, Zr, Nb, Mo, Hf, Ta and W. The magnet alloy particles may further include Ni and/or Al, or other alloying additions which provide the desired absorption characteristics. In a preferred embodiment, the magnetic alloy particles comprise an Fe—Cr—Ni—Al alloy. The insulating matrix of the electromagnetic wave absorbing material may comprise a water miscible polysilicate or a refractory cement. The materials may be provided in the form of coatings that are applied to a substrate, such as the hot engine exhaust area of an aircraft. The electromagnetic wave absorbing materials are capable of functioning at very high temperatures for extended periods of time while retaining satisfactory electromagnetic wave absorbing properties.

Abstract: A compressor having a corrosive resistant coating is disclosed. The coating has a first spray coated metallic layer. A sealant layer is disposed over the sprayed metallic coating which has an organic component, a solvent component, and an inorganic phase.

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.

Abstract: A wear-resistant layer is applied to a surface, which is to be protected, of a component which is subjected to mechanical and/or fluidic loads and substantially consists of amorphous or amorphous-nanocrystalline metals. The layer for protecting against abrasive or erosive wear substantially consists of an Ni—W-base alloy or substantially consists of an alloy based on Cu—Al—Ti(or —Ta or —Zr) or Pd—Cu—Si or Pt—Al—Si or Ta—Si—N, or substantially consists of an alloy of Al, at least one rare earth and a transition metal, such as Cu or Ni or Co.

Abstract: A kinetically sprayed magnetostrictive/magnetic material, comprising: magnetostriction particles; magnetic particles with coercivity; a ductile matrix for bonding the magnetostriction particles and magnetic particles with coercivity together; wherein an applied magnetic field will align the magnetic particles with coercivity and subsequently the magnetostriction particles such that the magnetostrictive material will produce a detectable change in the magnetostrictive/magnetic material when placed under an applied stress.

Abstract: The oxidation behavior of the bond coat is improved using a HVOF nanostructured NiCrAlY coating. NiCrAlY powder is mechanically cryomilled and HVOF sprayed onto Ni-based alloy to form a nanocrystalline bond coat. Oxidation is performed on the coating to form the thermally grown oxide layer (thermally grown oxide). After heat treatment at 1000° C. for 24 and 95 hour, a homogeneous &agr;-Al2O3 layer is formed on top of the bond coat. The nanostructured characteristic of the coating and the presence of Al2O3 within the cryomilled powders (oxidation occurred during cryomilling process) affects the nucleation of the alumina layer on the top of the coating. The formation of a continuous thermally grown oxide layer protects the coating from further oxidation and avoids the formation of mixed oxide protrusions, such as those presented in the coating sprayed using the as-received powder.

Abstract: A radiation-shielded system and method of producing a radiation-shielded system having at least one component susceptible to disruption upon exposure to ionizing radiation, wherein the susceptible component is protected by a rigid housing having a metallic layer of high atomic number that is deposited on the surface of the housing using a thermal spray technique.

Abstract: A method for protection of submerged marine surfaces from bio-fouling which is carried out by spraying the surface to be protected with a solvent free, zinc or zinc based alloy coating produced by a thermal spray process.

Abstract: The present invention provides a member coated with thermal barrier coating film having a metal substrate, the surface of which is covered with an adhesive layer (bond coat layer) composed of a heat resisting alloy and a thermal barrier film layer (thermal barrier coating layer) composed of a heat resisting ceramic formed on the adhesive layer, and a thermal spraying powder used for the formation of the adhesive layer, characterized in that the adhesive layer is a MCrAlX alloy (wherein M is at least one metal selected from among Fe, Ni and Co, and X is at least one metal selected from among Y, Hf, Ta, Cs, Pt Zr, La and Th), and an element capable of inhibiting the growth of an oxide layer (TGO) which is grown between the adhesive layer and the thermal barrier film layer by the exposure to a high temperature is added to the adhesive layer.

Abstract: A coated article having a high resistance to wear damage has a substrate, and a layered coating overlying the substrate. The layered coating includes a ductile metallic layer overlying and in facing contact with the substrate, and a protective layer overlying and in facing contact with the ductile metallic layer and including a mixture of a quasicrystalline metallic phase and a non-quasicrystalline ductile phase. The coated article is preferably used in applications where it is subjected to wear conditions.

Abstract: A wear alloy coating (14) applied to a substrate material (12) by a cold spray process. Particles of the wear alloy coating material (16) are directed toward a target surface (18) of the substrate at a velocity sufficiently high for the particles to deform and to adhere to the target surface. The size and composition of the particles may be varied during the cold spray process to produce a coating with a varying property across the depth of the coating. Particles of the wear alloy material may be applied by cold spraying along with particles of a second material such as a lubricant or a ceramic material. For Group 5 hard facing materials, the size and distribution of the embedded carbide nodules may be controlled by controlling the selection of the carbide particles being sprayed. The cold spray process permits a wear alloy coating to be applied proximate a brazed joint or over a directionally stabilized or single crystal material without degrading the underlying material.

Abstract: A group of alloys suitable for use in a high-temperature, oxidative environment, a protective coating system comprising a diffusion barrier that comprises an alloy selected from the group, an article comprising the diffusion barrier layer, and a method for protecting an article from a high-temperature oxidative environment comprising disposing the diffusion barrier layer onto a substrate are presented.

Abstract: A multiphase ceramic thermal barrier coating is provided. The coating is adapted for use in high temperature applications in excess of about 1200° C., for coating superalloy components of a combustion turbine engine. The coating comprises a ceramic single or two oxide base layer disposed on the substrate surface; and a ceramic oxide reaction product material disposed on the base layer, the reaction product comprising the reaction product of the base layer with a ceramic single or two oxide overlay layer.

Abstract: A metallic component exposed to high temperature steam is provided with a coating comprising a thin primer layer deposited on the surface of the metallic component and a thicker overlay layer on top of the primer layer. The primer layer consists of highly ductile, oxidation resistant material such that it remains free of any defects over a long period of exposure. The overlay layer consists of an oxidation resistant, less ductile, and low-cost material. It protects the thin primer layer from mechanical damage and chemical degradation. The primer layer protects the base material of the metallic component from oxidizing steam that may penetrate through cracks of the overlay layer. Due to suitable choice of coating materials and thicknesses of the layers the coating is low-cost.

Abstract: A method of providing a protective, corrosion-resistant thin coating of a MCrX alloy on a carbon or low-alloy steel pipe or tube where M is one of nickel, cobalt or iron or combination thereof and X is one of molybdenum, silicon, tungsten or combination thereof, and heat treating the coating to metallurgically bond the coating onto a steel substrate of the pipe or tube. The coating may be deposited in one or two layers by plasma transferred arc deposition or may be deposited as a slurry coating or thermal spray coating with sintering of the coating. The steel substrate is prepared for coating by at least one of boring, honing, bright finishing, grit blasting, grinding, chemical pickling or electro-polishing of the substrate.

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.

Abstract: The addition of small amounts of CeO2 and Cr to intermetallic compositions of NiAl and FeAl improves ductility, thermal stability, thermal shock resistance, and resistance to oxidation, sulphidization and carburization.

Abstract: The present invention provides a fuel tank or a fuel pipe excellent particularly in the corrosion resistance of the outer surface in a salt damage environment, and is a fuel tank or a fuel pipe excellent in corrosion resistance characterized by: being formed by using a steel sheet or a steel pipe containing Cr of 9.0 to 25.0 mass % as the base material; on the outer surface thereof, having any one or more of welded portions, brazed portions and structurally gapped portions contacting components; and having one or more of metals, whose electrode potential in a 5%-NaCl aqueous solution at 30° C. is −0.4 V or less relative to a saturated calomel electrode, attached to at least a part or parts of said portion(s) of the outer surface in an electrically conductive manner.

Abstract: A compressor having a corrosive resistant coating is disclosed. The coating has a first spray coated metallic layer. A sealant layer is disposed over the sprayed metallic coating which has an organic component, a solvent component, and an inorganic phase.

Abstract: The invention relates to a wear-resistant coating used for bearing surfaces and flanks of piston rings in internal combustion engines. The wear-resistant inventive coating is obtained by mechanically alloying powders which form a metallic matrix with hard material dispersoids and lubricant material dispersoids. The coating is then thermally applied to the workpieces, especially by means of high velocity oxygen fuel spraying (HVOF). The workpieces coated are bearing surfaces and parts of flanks pertaining to piston rings in internal combustion engines.

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.

Abstract: A method for forming a thermal barrier coating system on an article subjected to a hostile thermal environment, such as the hot gas path components of a gas turbine engine. The coating system is generally comprised of a ceramic layer and an environmentally resistant beta phase nickel aluminum intermetallic (&bgr;-NiAl) bond coat that adheres the ceramic layer to the component surface. A thin aluminum oxide scale forms on the surface of the &bgr;-NiAl during heat treatment. An additional layer of diffusion aluminide may can be formed underlying the ceramic layer. The &bgr;-NiAl may contain alloying elements in addition to nickel and aluminum in order to increase the environmental resistance of the &bgr;-NiAl. These elements include hafnium, chromium and zirconium and increase the oxidation resistance of the &bgr;-NiAl. The &bgr;-NiAl is supplied as a powder having a size in the range of 20-80 microns.

Abstract: In order to improve the wear resistance of the swash plate of a swash-plate type compressor, on which plate copper alloy is flame-sprayed, a composite material, which consists of copper or first copper alloy (for example Cu—Pb alloy) including at least unmelted phase and aluminum or first aluminum alloy (for example Al—Si alloy) including at least melted phase, is flame sprayed on the sliding surface with a shoe.

Abstract: The present invention relates to articles, having an extended useful life, which are used in contact with high temperature molten aluminum or molten zinc baths. One aspect of the invention encompasses articles, such as bearings, bushings, couplings or rollers, used in contact with molten aluminum or molten zinc which is coated with a high density coating consisting of a metal selected from Groups Vb, VIb, or VIIb metals (preferably molybdenum or tungsten), in pure or alloyed form. These coatings generally have a thickness of from about 0.06 to about 0.30 inch. Another aspect of the present invention encompasses a roll for guiding steel strip through a high temperature aluminizing bath, which utilizes a multi-layer structure, the first primer layer being a Group Vb, VIb or VIIb metal, preferably tungsten or molybdenum (in pure or alloyed form), the second layer comprising MCrAlY in which M is either nickel or cobalt, and the third layer comprising a refractory metal oxide of Al, Zr, Si or Cr.

Abstract: The invention relates to an aluminium alloy, in particular for a layer of a friction bearing, for example, which, apart from aluminium and smelt-related impurities, additionally contains soft-phase formers, e.g. Sn, Pb, Bi, Sb or similar. The alloy contains added quantities of at least one element from the group of elements consisting of Sc, Y, Hf, Nb, Ta, La, lanthanides and actinides in a maximum of 10% by weight, preferably 4% by weight, in particular between 0.015% by weight and 3.25% by weight, relative to 100% by weight of alloy, the remainder being aluminium with smelt-related impurities.

Abstract: The invention relates to an intermediate layer, in particular a bonding layer, made from an alloy with an aluminium base, for multi-layered materials with layers of differing composition, in particular friction bearings. The alloy contains added quantities of at least one element from a group of elements consisting of Sc, Y, Hf, Nb, Ta, La, lanthanides and actinides in a maximum of 10% by weight, preferably 4% by weight, in particular between 0.015% by weight and 3.25% by weight, relative to 100% by weight of alloy, the remainder being aluminium with smelt-related impurities.

Abstract: The invention concerns the use of a diffusion alloy metal powder for thermal coating of substrates. The powder comprises a pre-alloyed iron base powder particles having molybdenum particles diffusion alloyed to the particles of the base powder.

Abstract: In aluminum alloy which is required to have good sliding characteristics, excellent sliding characteristics are achieved by carrying out granulation while avoiding the formation of flakes from Si particles through thermally spraying an aluminum alloy containing Si in an amount of 12 to 60 % The aluminum alloy may contain 0.1 to 30% of Sn, in addition to Si.

Abstract: There is disclosed a material wire for wear-resistant and trobologically favorable shaped bodies manufactured by the arc spraying method, which comprises a covering (12) and a filling (14). The covering (12) comprises an alloy based on aluminium with at least one further alloy component, for example magnesium or manganese. The filling (14) comprises further alloy components for the resulting alloy of the shaped body, for example silicon. The filling (14) may apart from the silicon also comprise further components, for example aluminium and/or boron. By way of this the composition and the material properties of the resulting alloy of the shaped body may be set.

Abstract: A metallic tube for transporting corrosive, abrasive, and erosive industrial flow streams. The tube has an outer tube material consisting of consolidated metallic powder bonded to an inner tube material consisting of a corrosion- or wear-resistant, weld- or spray-deposited material. The tube has a bend in it of at least about 45°, such as a U-bend, which would normally inhibit the weld- or spray-deposition of the corrosion- or wear-resistant inner tube material.

Abstract: A roughened bond coat comprises a screen that includes interwoven wires defining openings and a metallic material disposed on the screen. The screen and metallic material form a roughened bond coat possessing an uneven, undulated, and irregular surface. The metallic material may be one of a slurry and a powder, and applied by coating and spraying, respectively. A thermal barrier coating system, which is formed with and incorporates the roughened bond coat, exhibits greater adhesion of a thermal barrier coating and bond coat due to an increased interfacial surface area provided by the uneven, undulated, and irregular surface.

Abstract: A method for providing a protective coating on a metal-based substrate is disclosed. The method involves the application of an aluminum-rich mixture to the substrate to form a discontinuous layer of aluminum-rich particles, followed by the application of a second coating over the discontinuous layer of aluminum-rich particles. Aluminum diffuses from the aluminum-rich layer into the substrate, and into any bond coat layer which is subsequently applied. Related articles are also described.

Abstract: A method of forming a plain bearing lining on a substrate, the method comprising high velocity oxy-fuel spraying particles of a bearing metal onto the substrate and treating said layer to form it into a lining.

Abstract: A titanium aluminide turbine blade (10) includes an aerofoil (12), a platform (14) and a root (16). A protective coating (2) is applied to the aerofoil (12) and the platform (14) of the turbine blade (10). The protective coating (2) comprises austenitic stainless steel. A chromium oxide layer (22) is formed on the protective coating (2). The protective coating (20) and chromium oxide layer (22) provides oxidation and sulphidation resistance for the titanium aluminide article (10).

Abstract: A high-strength lightweight steel and its use for car parts and facade linings is a purely ferritic steel having, in mass %, more than 5 to 9% Al, less than 0.2% Si, and 0.03 to 0.2% Mn.

Abstract: A bond coat and method of forming a bond coat for a thermal barrier coating system are set forth. The bond coat is a roughened bond coat and comprises a layer possessing an uneven, undulated, and irregular surface. The layer is formed of a metal powder mixture disposed on a substrate, such as a turbine component, by high velocity oxygen fuel spraying. The metal powder mixture comprises at least one of a first powder having a first melting point and a second powder having a second melting point that is higher than the first melting point. The bond coat's uneven, undulated, and irregular surface enhances prevention of de-bonding of elements in a thermal barrier coating system.