Abstract: Methods for repairing flange bolt holes and the resulting flange bolt holes are provided. The methods and products include the incorporation of a coating system comprising a corrosion resistant layer, which can be formed by resistance plug welding, slurry or sol-gel processing, or thermal/cold spray processing. The corrosion resistant layer can be a super alloy or ceramic material and is different than the base material of the flange bolt hole. Corrosion of the flange bolt hole can be reduced or prevented from occurring with the use of the coating system.

Abstract: A silicone bond coat composition having a viscosity of less than 1,600 centistokes is applied to substantially all external surfaces of the article and then cured. A liquid silicone elastomer outer coat composition comprising a high viscosity first liquid silicone elastomer formulation and a low viscosity second liquid silicone elastomer formulation is then applied and cured to provide a protected article having a complex shape. Optimal coatings result from a careful balancing of component viscosities. In an embodiment, the first formulation has a viscosity greater than 300,000 centistokes, and the second formulation has a viscosity less than 6,000 centistokes, and the liquid silicone elastomer outer coat composition comprises from about 60 to about 40 percent by weight of the first formulation and from about 40 to about 60 percent by weight of the second liquid silicone elastomer formulation.

Abstract: Methods for repairing flange bolt holes and the resulting flange bolt holes are provided. The methods and products include the incorporation of a coating system comprising a corrosion resistant layer, which can be formed by resistance plug welding, slurry or sol-gel processing, or thermal/cold spray processing. The corrosion resistant layer can be a super alloy or ceramic material and is different than the base material of the flange bolt hole. Corrosion of the flange bolt hole can be reduced or prevented from occurring with the use of the coating system.

Abstract: A silicone bond coat composition having a viscosity of less than 1,600 centistokes is applied to substantially all external surfaces of the article and then cured. A liquid silicone elastomer outer coat composition comprising a high viscosity first liquid silicone elastomer formulation and a low viscosity second liquid silicone elastomer formulation is then applied and cured to provide a protected article having a complex shape. Optimal coatings result from a careful balancing of component viscosities. In an embodiment, the first formulation has a viscosity greater than 300,000 centistokes, and the second formulation has a viscosity less than 6,000 centistokes, and the liquid silicone elastomer outer coat composition comprises from about 60 to about 40 percent by weight of the first formulation and from about 40 to about 60 percent by weight of the second liquid silicone elastomer formulation.

Abstract: A method for repairing a component is provided. The method comprises: tracing an electrode across a defect/damage on the component at a preselected distance from the component; feeding a first metal powder and a second metal powder into a discharging gap between the electrode and the component; controlling feed rates of the first and second metal powders separately; and electro-spark depositing the first and second metal powders to the component to form a hybrid metal coating. The first metal powder comprises a first metal or alloy with a Vickers hardness rating of about 70-200% of the Vickers hardness rating of the component. The second metal powder comprises a second metal or alloy having lubricating/anti-corrosion properties.

Abstract: A coating method and a coated article are disclosed. Forming a coating includes providing a substrate having a substrate surface, forming on the substrate surface at least one bond coating layer defining a bond coating surface, and forming on the bond coating surface at least one oxide coating layer defining an oxide coating surface. A coated article includes a substrate having the coating formed thereupon. The oxide coating layer is more resistive to increasing the oxide coating surface roughness (Ra) than either the bond coating layer is resistive to increasing the bond coating surface roughness (Ra) or the substrate is resistive to increasing the substrate surface roughness (Ra).

Abstract: A coated article and a method for producing a coating are disclosed. Producing the coating includes providing a substrate defining a substrate surface having a substrate erosion resistance and applying a matrix and ceramic particles to the substrate surface. The matrix includes an anodic material having an anodic erosion resistance. The ceramic particles include a first ceramic having a first ceramic erosion resistance and a second ceramic having a second ceramic erosion resistance. The first ceramic erosion resistance is greater than the second ceramic erosion resistance, greater than the anodic erosion resistance, and greater than the substrate erosion resistance. The second ceramic interacts inchoately with the anodic material during the applying to form modified ceramic particles and modified anodic material formations. The modified ceramic particles are capable of forming a passive oxide film. The coated article includes the substrate and the coating on the substrate surface.

Abstract: A submersible pump component is provided. The component includes a substrate including an outer surface in a plurality of orientations, wherein a first portion of the outer surface is configured to be worn by a first wear mechanism, and a second portion of said outer surface is configured to be worn by a second wear mechanism. The component also includes at least one layer of a first coating applied to the outer surface, and at least one layer of a second coating applied over said first coating at said second portion of said outer surface. The first coating is configured to inhibit the first wear mechanism at the first portion of the outer surface, and the second coating is configured to inhibit the second wear mechanism at the second portion of the outer surface.

Abstract: A method for repairing a component is provided. The method comprises: tracing an electrode across a defect/damage on the component at a preselected distance from the component; feeding a first metal powder and a second metal powder into a discharging gap between the electrode and the component; controlling feed rates of the first and second metal powders separately; and electro-spark depositing the first and second metal powders to the component to form a hybrid metal coating. The first metal powder comprises a first metal or alloy with a Vickers hardness rating of about 70-200% of the Vickers hardness rating of the component. The second metal powder comprises a second metal or alloy having lubricating/anti-corrosion properties.