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: Improved wear resistant coatings are provided based upon a novel abrasion resistance factor (R) for a given average size of abrasive fine particles. The improved wear resistant coatings exhibit minimal oxide content and minimal porosity, while exhibiting improved wear resistance and hardness. The improved wear resistant coatings are made from a composite material consisting of a hard phase and a metallic binder derived from powder particle sizes ranging from about 0.5 ?m-30 ?m as part of a modified thermal spray process.

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: 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: 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 fully-dense, fluid tight, low friction coating system is described that is characterized by fluid impermeability and a reduced coefficient of friction. The coating system includes a fully dense, fluid tight underlying layer; and a low friction layer. Unlike conventional materials requiring a sealant, the coating systems of the present invention achieves better fluid tightness and maintains said fluid tightness along one or more sealing surfaces at higher service temperatures and service pressures than previously attainable. The constituents of the fully-dense, fluid tight, low friction coating system are physically and chemically compatible so as to not adversely impact lubricity, wear resistance and corrosion resistance during the service life of a component coated with the fully-dense, fluid tight, low friction coating system.

Abstract: A fully-dense, fluid tight, low friction coating system is described that is characterized by fluid impermeability and a reduced coefficient of friction. The coating system includes a fully dense, fluid tight underlying layer; and a low friction layer. Unlike conventional materials requiring a sealant, the coating systems of the present invention achieves better fluid tightness and maintains said fluid tightness along one or more sealing surfaces at higher service temperatures and service pressures than previously attainable. The constituents of the fully-dense, fluid tight, low friction coating system are physically and chemically compatible so as to not adversely impact lubricity, wear resistance and corrosion resistance during the service life of a component coated with the fully-dense, fluid tight, low friction coating system.

Abstract: A protective coating system is described that is characterized by fluid impermeability and a reduced coefficient of friction. The coating system includes a carbide-based thermal spray composition; a low friction layer; and a sealant impregnated into the low friction layer. Unlike conventional materials, the coating systems of the present invention achieve and maintain sealing surfaces, without adversely impacting lubricity, wear resistance and corrosion resistance during the service life of the coated component.