Abstract: A fuel injector body comprising a fuel line defined by a passage therethrough and a ceramic cylinder disposed within the passage. The ceramic cylinder is a tube including a hollow passage for fuel flow therethrough. In addition, a method of protecting the fuel lines of a fuel injector is disclosed, comprising the steps of inserting a ceramic cylinder into at least passage for a fuel line of the fuel injector and adhering the ceramic cylinder within the passage.

Abstract: The invention provides a method for forming a thermal barrier coating having vertical cracks for improved thermal and mechanical stress tolerance. The method can include depositing a first sub-layer on a substrate at a first temperature T1, followed by depositing a second sub-layer on the first sub-layer at a second temperature T2, wherein T2 is less than T1 such that a temperature gradient having a negative heat flux toward the top of the second sub-layer is created, thereby introducing thermal stress in the sub-layers causing vertical cracks to be formed in the sub-layers. The method then involves repeating steps (a) and (b) for n cycles to form the thermal barrier coating comprising the vertical cracks, wherein n is an integer from 1 to 200.

Abstract: The present invention provides methods for producing a crack-free abradable coating with enhanced adhesion. The methods include the steps of providing a substrate and applying an abradable material to the substrate, either directly or indirectly via one or more additional layers. A critical coating temperature of the abradable material is determined that ensures that the thermal stress level in the abradable material is lower than the tensile strength of the abradable material. The temperature of the abradable material is held at a constant temperature below the critical coating temperature throughout the step of applying the abradable material to the substrate.

Abstract: Coated nickel, cobalt or nickel-cobalt superalloy bodies having increased resistance to oxidation, corrosion and thermal fatigue at high temperature are produced by applying a thin layer of a platinum-group metal, siliciding and heating to an elevated temperature to diffuse and integrate the silicided platinum-group metal into the surface of the superalloy body. Then the superalloy body is exposed to a diffusion powder composition containing sources of aluminum or aluminum/chromium metals and heated in a hydrogen or inert gas atmosphere to an elevated temperature to codeposit and diffuse aluminum or aluminum and chromium into the silicided platinum-group metal-treated surface layer.

Abstract: Process for producing novel coated nickel and/or cobalt superalloy bodies having increased resistance to oxidation, corrosion and thermal fatigue at high temperatures. The process comprises applying a thin layer of a platinum-group metal, siliciding and heating to an elevated temperature to diffuse and integrate the silicided platinum-group metal into the surface of the superalloy body. Then the superalloy body is exposed to a diffusion powder composition containing sources of aluminum or aluminum/chromium metals and heated in a hydrogen or inert gas atmosphere to an elevated temperature to codeposit and diffuse aluminum or aluminum and chromium into the silicided platinum-group metal-treated surface. Finally, the superalloy body is heated to its solvus temperature to form a ductile surface having an outer zone comprising a platinum-group metal aluminide, optionally ductilized by the solutioning therein of beta chromium.

Abstract: Process for producing novel nickel superalloy bodies having increased resistance of to oxidation and corrosion at high temperatures. The process comprises applying a thin layer of a platinum-group metal and heating to an elevated temperature to diffuse or integrate the platinum-group metal into the surface of the metal superalloy. Then the superalloy body is packed into a container filled with a diffusion powder composition containing sources of aluminum and chromium metals and heated in a hydrogen gas atmosphere to an elevated temperature to codeposit and diffuse aluminum and chromium into the platinum-group metal-treated surface. Finally, the superalloy body is removed from the diffusion coating container and heated to the solvus temperature to form a ductile surface having an outer zone microstructure comprising a normally brittle PtAl.sub.2 which has been ductilized by the solutioning therein of beta chromium. This ductilized PtAl.sub.