Abstract: Zirconia-containing ceramic compositions having a c/a ratio of the zirconia lattice in the range of from about 1.005 to about 1.016. These compositions comprise a stabilizing amount up to about 10 mole % of the composition of a stabilizer component which comprises: (1) a first metal oxide selected from the group consisting of yttria, calcia, ceria, scandia, magnesia, india and mixtures thereof in an amount of from about 1.5 to about 6 mole % of the composition of; (2) a second metal oxide selected from the group consisting of lanthana, neodymia and mixtures thereof in an amount of from about 0.5 to about 4 mole % of the composition; and (3) optionally ytterbia in an amount of from about 0.5 to about 4 mole % of the composition. These compositions further comprise hafnia in an amount of from about 0.5 to about 15 mole % of the composition; and optionally tantala in an amount of from about 0.5 to about 1.5 mole % of the composition.

Abstract: A fuel cell stack includes at least one fuel cell unit and a number of interconnects defining at least two openings and including at least one flow field for flowing a reagent. Each opening defines a respective fuel manifold, including at least one each of intake and exhaust fuel manifolds. The fuel cell unit includes an anode, a cathode, and an electrolyte disposed therebetween. The anode is adjacent to and in both electrical connection and fluid communication with one of the interconnects, which has a flow field that guides a fuel flow between the intake and exhaust fuel manifolds. The cathode is adjacent to and in both electrical connection and fluid communication with another interconnect with a flow field that guides an oxidant flow. The fuel cell stack includes a perimeter isolation seal and at least two interior isolation seals for sealing the electrolyte to the respective interconnects.

Abstract: A fuel cell and a method for manufacturing a fuel cell are presented. The method comprises providing at least one substrate and disposing a plurality of fuel cell component layers on the substrate by at least one physical vapor deposition process. Each layer of the plurality comprises an edge bordering the layer. The fuel cell unit comprises at least one substrate; a plurality of fuel cell component layers disposed on the substrate, wherein each layer of the plurality comprises an edge bordering the layer; and at least one dense layer of material disposed over at least a portion of the edge of at least one fuel cell component layer. The at least one dense layer seals at least the aforementioned portion of the edge.

Abstract: A fuel cell stack includes at least one fuel cell unit and a number of interconnects defining at least two openings and including at least one flow field for flowing a reagent. Each opening defines a respective fuel manifold, including at least one each of intake and exhaust fuel manifolds. The fuel cell unit includes an anode, a cathode, and an electrolyte disposed therebetween. The anode is adjacent to and in both electrical connection and fluid communication with one of the interconnects, which has a flow field that guides a fuel flow between the intake and exhaust fuel manifolds. The cathode is adjacent to and in both electrical connection and fluid communication with another interconnect with a flow field that guides an oxidant flow. The fuel cell stack includes a perimeter isolation seal and at least two interior isolation seals for sealing the electrolyte to the respective interconnects.

Abstract: A method for forming a thermal barrier coating system on a turbine engine component includes forming a bondcoat on the turbine engine component and depositing a thermal barrier coating so as to overlie the bondcoat. The bondcoat is formed by thermally co-spraying first and second distinct alloy powders on the turbine engine component forming an oxidation-resistant region, and thermally spraying a third alloy powder on the oxidation-resistant region to form a bonding region.

Abstract: A thermal barrier coating (TBC 26) and method for forming the TBC (26) on a component (10) characterized by a stabilized microstructure that resists grain growth, sintering and pore coarsening or coalescence during high temperature excursions. The TBC (26) contains elemental carbon and/or a carbon-containing gas that increase the amount of porosity (32) initially within the TBC (26) and form additional fine closed porosity (32) within the TBC (26) during subsequent exposures to high temperatures. A first method involves incorporating elemental carbon precipitates by evaporation into the TBC microstructure. A second method is to directly incorporate an insoluble gas, such as a carbon-containing gas, into an as-deposited TBC (26) and then partially sinter the TBC (26) to entrap the gas and produce fine stable porosity within the TBC (26).

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 for applying a wear coating on a surface of a substrate is described. A foil of the wear coating is first attached to the substrate surface, and then fused to the surface, e.g., by brazing. The wear coating may be formed from a carbide-type material. The substrate is very often a superalloy material, e.g., a component of a turbine engine. A method for repairing a worn or damaged wear coating applied over a substrate is also described, along with related articles of manufacture.

Abstract: A method for forming a thermal barrier coating system on a turbine engine component includes forming a bondcoat on the turbine engine component and depositing a thermal barrier coating so as to overlie the bondcoat. The bondcoat is formed by thermally co-spraying first and second distinct alloy powders on the turbine engine component forming an oxidation-resistant region, and thermally spraying a third alloy powder on the oxidation-resistant region to form a bonding region.

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 for applying a wear coating on a surface of a substrate is described. A foil of the wear coating is first attached to the substrate surface, and then fused to the surface, e.g., by brazing. The wear coating may be formed from a carbide-type material. The substrate is very often a superalloy material, e.g., a component of a turbine engine. A method for repairing a worn or damaged wear coating applied over a substrate is also described, along with related articles of manufacture.

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 for forming a thermal barrier coating system on a turbine engine component includes forming a bondcoat on the turbine engine component and depositing a thermal barrier coating so as to overlie the bondcoat. The bondcoat is formed by thermally co-spraying first and second distinct alloy powders on the turbine engine component forming an oxidation-resistant region, and thermally spraying a third alloy powder on the oxidation-resistant region to form a bonding region.

Abstract: A method for applying a wear coating on a surface of a substrate is described. A foil of the wear coating is first attached to the substrate surface, and then fused to the surface, e.g., by brazing. The wear coating may be formed from a carbide-type material. The substrate is very often a superalloy material, e.g., a component of a turbine engine. A method for repairing a worn or damaged wear coating applied over a substrate is also described, along with related articles of manufacture.

Abstract: A method for applying a wear coating on a surface of a substrate is described. A foil of the wear coating is first attached to the substrate surface, and then fused to the surface, e.g., by brazing. The wear coating may be formed from a carbide-type material. The substrate is very often a superalloy material, e.g., a component of a turbine engine. A method for repairing a worn or damaged wear coating applied over a substrate is also described, along with related articles of manufacture.