Abstract: Method for forming a molded part and the molded part. The method includes applying a thermal barrier coating (TBC) system to a sand core; inserting the TBC coated sand core into a mold; and forming a cast iron part in the mold with the inserted TBC coated sand core.

Abstract: The invention relates to a coating lance for a plasma process, the lance comprising a plasma shaft, a plasma neck, and a plasma head, the plasma shaft comprising a longitudinal channel, which extends in an axial direction along an axis from a first shaft end to a second shaft end, the plasma neck comprising a shaft boss and a head boss and at least one neck channel, which extends from the shaft boss to the head boss, and the shaft boss being arranged on the second shaft end in such a way that the longitudinal channel leads into the at least one neck channel, the plasma head comprising a neck boss, a plasma opening, and at least one head channel, which extends from the neck boss to the plasma opening, and the neck boss of the plasma head being arranged on the head boss of the plasma neck in such a way that the at least one neck channel leads into the head channel.

Abstract: A thermal spray cabin comprising a table to hold a part to be coated and a robot with a robot body and an arm, a spray gun mounted on the arm of the robot, a ventilation system comprising an air inlet and a suction hood designed to create a gas flow with a main stream from the air inlet to the suction hood thereby passing the table in an operating state of the thermal spray cabin. The air inlet, the table, the robot and the suction hood are arranged in such a way, that the robot body is positioned outside the main stream of the gas flow in the operating state.

Abstract: Method of cleaning a plasma coating torch utilizing at least one nozzle mounted so as to be directed at the plasma coating torch in order to subject an external surface of the plasma coating torch to a cleaning agent that removes spray material particles which have adhered to the external surface of the plasma coating torch during coating with the plasma coating torch, and such that the cleaning agent exiting the at least one nozzle and being directed toward the external surface and directly changing to a gaseous state from either a solid state or a liquid state.

Abstract: A plasma spraying device includes a torch head which has a plasma channel that extends between a cathode and an anode. The plasma channel is bounded by a plurality of neutrodes which are electrically insulated from each other. A gap extends between the frontmost neutrode and the anode, which gap is divided into at least two sections. There is a radial distance and an axial distance between the two sections. An insulating disk is arranged in each of the two sections.

Abstract: Cylinder of piston-type internal combustion engine includes at least one bore with inner shell formed from a base material. The base material, in a region of the bore, includes a layer system, and a first boundary surface formed between base material and layer system. Layer system includes at least one thermally sprayed layer forming at least partially a shell surface of the bore and acts there as a functional layer. First boundary surface does not include any profiling applied for mechanical activation of the surface apart from surface roughness resulting from manufacture of the bore. The material of the layer system includes molybdenum and at least one further element in the region of the boundary surface to the base material and is bonded to the base material by a chemical bond. This boundary surface material differs from the material of the functional layer in composition and/or structure.

Abstract: Plasma nozzle includes a nozzle body arranged to engage with a thermal spray gun. The nozzle body includes an axial through bore having up-stream input orifice and a down-stream nozzle exit, at least one material injector positioned between the up-stream input orifice and the nozzle-exit, said at least one material injector being configured to introduce a feedstock material into a gas flow passing through the axial through bore and at least one gas injector configured to introduce a shroud gas flow into the axial through bore and being located at a position up-stream of said at least one material injector.

Abstract: A thermal spray cabin comprising a table to hold a part to be coated and a robot with a robot body and an arm, a spray gun mounted on the arm of the robot, a ventilation system comprising an air inlet and a suction hood designed to create a gas flow with a main stream from the air inlet to the suction hood thereby passing the table in an operating state of the thermal spray cabin. The air inlet, the table, the robot and the suction hood are arranged in such a way, that the robot body is positioned outside the main stream of the gas flow in the operating state.

Abstract: Method of cleaning a plasma coating torch utilizing at least one nozzle mounted so as to be directed at the plasma coating torch in order to subject an external surface of the plasma coating torch to a cleaning agent that removes spray material particles which have adhered to the external surface of the plasma coating torch during coating with the plasma coating torch, and such that the cleaning agent exiting the at least one nozzle and being directed toward the external surface and directly changing to a gaseous state from either a solid state or a liquid state.

Abstract: Method for coating components by thermal spraying, wherein not the entire surface of the component is to be coated and wherein those parts of the surface that are not to be coated are covered by masking before coating and wherein the covering is made by a paste processes at least in the areas of critical mask boundaries, i.e. by way of a paste dispensed from at least one nozzle, wherein the paste is a curable paste and curing is photo induced and preferably made by way of UV radiation, characterized in that the masking utilizes a partial masking step and a complementary masking step, the complementary masking step being performed at least in the area of critical mask boundaries and the partial masking step being performed in an area spaced from the area of critical mask boundary and the method of partial masking is not a paste process.

Abstract: A rotary feedthrough for the feedthrough of a powder-gas mixture from a stationary machine part into a rotating machine part, with a seal in the form of two flat circular-ring-shaped sliding seal surfaces arranged one on the other in a sliding manner, which sliding seal surfaces are arranged concentric to the axis of rotation of the rotating machine part and which can be moved apart from each other in the axial direction, so that they form a gap, wherein the seal is embedded in a purge chamber having at least one gas inlet and at least one gas outlet.

Abstract: The invention relates to a coating lance for a plasma process, the lance comprising a plasma shaft, a plasma neck, and a plasma head, the plasma shaft comprising a longitudinal channel, which extends in an axial direction along an axis from a first shaft end to a second shaft end, the plasma neck comprising a shaft boss and a head boss and at least one neck channel, which extends from the shaft boss to the head boss, and the shaft boss being arranged on the second shaft end in such a way that the longitudinal channel leads into the at least one neck channel, the plasma head comprising a neck boss, a plasma opening, and at least one head channel, which extends from the neck boss to the plasma opening, and the neck boss of the plasma head being arranged on the head boss of the plasma neck in such a way that the at least one neck channel leads into the head channel.

Abstract: A method of forming an abradable coating includes forming a plasma; introducing a coating material, as a powder having particles in the range between 1 and 50 ?m, carried by a delivery gas into the plasma, having a sufficiently high specific enthalpy for at least partially melting some of the powder and vaporizing at least 5% by weight of the powder, to form a vapor phase cloud of vapor and particles; forming a plasma beam by maintaining a process pressure between 50 and 2000 Pa; defocussing the plasma beam by maintaining a process pressure between 50 and 2000 Pa; and forming from the vapor phase cloud an abradable coating, comprising columnar structures. Advantageously, the columnar structured abradable coating has an erosion resistance smaller than 30 s/mils, preferably in the range of 5 to 27 s/mils, more preferably in the range 10-25 s/mils, still more preferably in the range 15-20 s/mils.

Abstract: Processing apparatus for processing a workpiece surface in form of an internal coating of cylinder bores which are arranged in a row. The apparatus includes a shield unit which is provided to separate from one another—at least during operation—a part region of the workpiece surface provided for the processing and an adjacently arranged part region of the workpiece surface, whereby the shield unit has at least one blocking nozzle which is provided to generate a fluid flow for separating the at least two part regions, wherein the blocking nozzle is positioned such that the fluid flow flows along the workpiece surface and the blocking nozzle is directed to the part region between two cylinder bores.

Abstract: Processing apparatus and method for processing a workpiece surface, in particular for the internal coating of cylinder bores. Processing apparatus has a shield unit which is provided to separate from one another-at least during operation-a part region of the workpiece surface provided for the processing and an adjacently arranged part region of the workpiece surface. The shield unit has at least one blocking nozzle which is provided to generate a fluid flow for separating the at least two part regions.

Abstract: Method for the manufacture of a coating having a columnar structure, preferably a dense structure, in which method a coating material in the form of primary corpuscles is injected with a carrier gas into a thermal process beam. The coating material is transferred into a vapor phase in the process beam and is deposited as a condensate in the form of a columnar coating on a substrate. The primary corpuscles are formed by an agglomerate of particles which are held together by cohesive forces of a connecting medium or by adhesive forces.

Abstract: The invention relates to a coating method for coating a curved surface (1), in particular a concave inner surface (1) of a bore wall or a cylinder wall (2), by means of a powdery coating material (3) by using a thermal spraying device, in particular a plasma spraying device (4) or a HVOF spraying device. A gun (6) is provided on a gun shaft (5) of the thermal spraying device (4) for generating a coating jet (7) from the powdery coating material (3) by means of an arc and the gun (6) is rotated about a shaft axis (A) of the gun shaft (5) at a predetermined rotation frequency (N), wherein the coating jet (7) for applying a coating (8) to the curved surface (1) is directed at least partially radially away from the shaft axis (A) towards the curved surface (1).

Abstract: Cylinder of piston-type internal combustion engine includes at least one bore with inner shell formed from a base material. The base material, in a region of the bore, includes a layer system, and a first boundary surface formed between base material and layer system. Layer system includes at least one thermally sprayed layer forming at least partially a shell surface of the bore and acts there as a functional layer. First boundary surface does not include any profiling applied for mechanical activation of the surface apart from surface roughness resulting from manufacture of the bore. The material of the layer system includes molybdenum and at least one further element in the region of the boundary surface to the base material and is bonded to the base material by a chemical bond. This boundary surface material differs from the material of the functional layer in composition and/or structure.

Abstract: Method for the manufacture of a hydrogen-permeable membrane having a thickness of not greater than 30 ?m. The method includes plasma spraying at least one dense layer on a porous substrate such that during the plasma spraying, one sweep of a process beam deposits material particles over the substrate in a form of individual splats which do not produce a cohesive layer and said material particles include a proton-conducting ceramic material and an electron-conducting metallic component. The plasma spraying is LPPS-TF that utilizes a spraying distance of between 200 mm and 2000 mm, a sprayable powder starting material having a particle size range between 1 and 80 ?m and containing the proton-conducting ceramic material and the electron-conducting metallic component and a process beam dispersing the sprayable powder starting material to a cloud.