Abstract: Hexavalent chromium-free slurry formulations which are suitable in the production of inorganic overlay coating systems are described. The formulations provide superior hot corrosion and high-temperature oxidation protection for superalloy substrates. A basecoat slurry and topcoat slurry are provided. The basecoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:P higher than about 1:3 with the incorporation of pigments of either metallic particles, or metal oxide particles, or both in combination. The topcoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:P higher than about 1:3. An inorganic overlay coating formed on substrate made from the slurry formulation of present invention for hot corrosion protection on superalloy substrate against hot corrosion.

Abstract: This invention relates to a thin and texturized film that can be applied onto a non-smooth surface to improve hardness, corrosion resistance and wear resistance properties of the surface while maintaining the underlying profile of the non-smooth surface. An additive overlaying process can be employed to produce the thin and texturized film on the non-smooth surfaces without substantial alteration or degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The thin and texturized film fully covers the non-smooth in a uniform manner and maintains the surface profile.

Abstract: A fluid tight, fully-densified, coating is prepared by a High Velocity Oxygen Fuel (“HVOF”) process that dilutes oxygen with an inert gas. The inert gas is pre-mixed with oxygen prior to the oxygen entering a combustion chamber. The resultant flame temperature is lowered a controlled amount to eliminate, minimize or reduce oxidation of power feedstock that is injected into the thermal spray torch. The ability to reduce the flame temperature allows a relatively smaller particle feedstock to be deposited without significant oxidation. The dilution process creates an as-deposited fully-dense, fluid tight coating.

Abstract: Polyurethane-based coatings which exhibit superior erosion and heat resistance combined with antifouling and chemical resistance that are useful for protection of metal components are provided. The coatings are characterized by enhanced particle erosion resistance and enhanced heat resistance and are derived from specific multicomponent slurry compositions.

Abstract: Hexavalent chromium-free slurry formulations which are suitable in the production of ceramic overlay coating systems are described. The formulations provide superior hot corrosion and heat oxidation protection for superalloy substrates. A basecoat slurry and topcoat slurry are provided. The basecoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:PO4 higher than about 1:3 with the incorporation of metal oxide particles. The topcoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:PO4 higher than about 1:3. Both of the basecoat slurry and the topcoat slurry are hexavalent chromium-free.

Abstract: This invention relates to a thin and texturized film that can be applied onto a non-smooth surface to improve hardness, corrosion resistance and wear resistance properties of the surface while maintaining the underlying profile of the non-smooth surface. An additive overlaying process can be employed to produce the thin and texturized film on the non-smooth surfaces without substantial alteration or degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The thin and texturized film fully covers the non-smooth in a uniform manner and maintains the surface profile.

Abstract: Hexavalent chromium-free slurries are provided that are capable of achieving a full cure at temperatures as low as 330-450 degrees F., thus making the coatings especially suitable for application on temperature sensitive base materials. The slurries are suitable in the production of protective coating systems formed by novel silicate-based basecoats that are sealed with novel phosphate-based topcoats. The coating systems exhibit acceptable corrosion and heat resistance and are capable of replacing traditional chromate-containing coating systems.

Abstract: A composition based on a certain chromium-free silicate-based binder is described. The composition is an aqueous solution of lithium-doped potassium silicate in combination with an aluminum or aluminum alloy powder, zinc powder or a combination thereof. The coatings of the present invention are capable of achieving a full cure at temperatures as low as 350-450 degrees F. by the inclusion of a colloidal solution of a nano-sized ceria, thus making the coatings especially suitable for application on temperature sensitive base materials.

Abstract: This invention relates to thermal spray coatings and processes onto non-smooth surfaces. The coating and processes can coat non-smooth surfaces without substantial degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The ability for coating fractional coverage to maintain the surface profile while maintaining wear resistance is unprecedented by conventional thermal spray processes.

Abstract: This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of verticalzA macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

Abstract: This invention relates to thermally sprayed coatings of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

Abstract: A composition based on a certain chromium-free silicate-based binder is described. The one-part slurry composition is an aqueous solution of lithium-doped potassium silicate in combination with an aluminum or aluminum alloy powder. The one-part slurry composition produces a corresponding coating exhibiting improved performance at a reduced coating thickness.

Abstract: This invention relates to thermal spray coatings, powders useful in deposition of the thermal spray coatings, methods of producing the powders, and uses of the thermal spray coatings, for example, coating of piston rings and cylinder liners of internal combustion engines. The coatings of this invention are applied by thermal spray deposition of a powder. The powder contains bimetallic carbides of chromium and molybdenum dispersed in a matrix metal. The matrix metal contains nickel/chromium/molybdenum.

Abstract: This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

Abstract: A composition based on a novel MCrAlY formulation is provided for the production of protective coatings. The specific combination of the constituents of the MCrAlY formulation advantageously allows significantly high loadings of ceramic (metal oxide) while still retaining the ability to selectively oxidize aluminum to form alumina scale, a property previously not attainable with conventional MCrAlY materials when loaded with ceramics at levels of 15-45 weight percent. The alumina scale in combination with the modified MCrAlY formulation act as a barrier to specific detrimental oxide formations. The compositions of the present invention can act as protective coatings for a wide array of applications.

Abstract: Polyurethane composition based on a certain polyether and polyester prepolymer reaction mixture, wherein the composition is utilized in manufacturing chemical mechanical polishing/planarizing (CMP) pads. The CMP pads have low rebound and can dissipate irregular energy as well as stabilize polishing to yield improved uniformity and less dishing of the substrate.

Abstract: This invention relates to thermally spray coated work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture comprising a cylindrical-like structure having an outer peripheral surface and a thermally sprayed coating on the outer peripheral surface of said cylindrical-like structure, said thermally sprayed coating comprising from about 65 to about 95 weight percent of one or more Group VI metal carbides, and from about 5 to about 35 weight percent of one or more transition metals selected from chromium, manganese, iron, cobalt and nickel. This invention also relates to a process for preparing the work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture, a method for manufacturing metal or metal alloy, e.g., aluminum alloy, sheet using the thermally spray coated work rolls, and a thermal spray powder for coating the outer peripheral surface of the work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture.

Abstract: This invention relates to rolls for use in or in contact with molten metal comprising a roll drum having an outer peripheral surface and a thermally sprayed coating on the outer peripheral surface of said roll drum, said thermally sprayed coating comprising from about 66 to about 88 weight percent of tungsten, from about 2.5 to about 6 weight percent of carbon, from about 6 to about 20 weight percent of cobalt, and from about 2 to about 9 weight percent of chromium; a process for preparing the rolls; a method for forming a metal layer on a metal sheet utilizing the rolls, e.g., galvanization; and a thermal spray powder for coating the outer peripheral surface of the rolls.

Abstract: This invention relates to dense, vertically cracked thermal barrier coatings made from high purity yttria or ytterbia stabilized zirconia powders. The high purity yttria or ytterbia stabilized zirconia powder consisting essentially of less than about 0.01 weight percent silicon dioxide (silica), less than about 0.002 weight percent aluminum oxide (alumina), less than about 0.005 weight percent calcium oxide, less than about 0.005 weight percent ferric oxide, less than about 0 to about 0.002 weight percent magnesium oxide, less than about 0 to about 0.005 weight percent titanium dioxide, from about 1.5 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria), less than 0.1 weight percent other impurity oxides, and the balance zirconium oxide (zirconia) and the balance zirconium oxide (zirconia).

Abstract: The method forms a sputter target assembly by attaching a sputter target to an insert and applying a bond metal layer between the insert and a backing plate. Then pressing the insert and backing plate together forms a solid state bond with the bond metal layer, attaches the insert to the backing plate and forms at least one cooling channel between the insert and the backing plate.