Abstract: A manufacturing process includes depositing a clad layer having a thickness greater than about 0.5 mm (0.02 in) on a surface of the component by hardfacing, and creating a heat affected zone directly below the clad layer due to the depositing. The heat affected zone may be a region of the component where a lowest hardness is lower than a base hardness of the component below the heat affected zone. The method may also include heat treating the component after the deposition such that the lowest hardness in the heat affected zone is restored to within about 15% of the base hardness of the component.

Abstract: A laser cladding system includes a laser apparatus, a chamber, and a pump system. The laser apparatus is configured to generate a laser beam. The chamber includes an interior surface that defines a cladding area comprising a sealed volume. The chamber includes a window that is made from a laser-transparent material and is configured to allow the laser beam to pass therethrough into the cladding area. The pump system has a port in communication with the cladding area. The pump system is configured to selectively generate a vacuum pressure within the cladding area sufficient to evacuate gas from within the cladding area out through the port. The laser apparatus includes a laser head from which the laser beam is emitted and a robotic laser motion system configured to selectively move the laser head such that the laser beam moves relative to a reference point within the chamber.

Abstract: Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.

Abstract: Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.

Abstract: A component includes a body and a wear layer. The body has a substrate surface. The wear layer is applied to the body such that the wear layer is in overlying relationship with at least a portion of the substrate surface. The wear layer is thermal-spray bonded to the body. The wear layer comprises a composite of a steel alloy and a copper alloy.

Abstract: A process of remanufacturing a component such as an attachment flange used in turbochargers is provided and includes using a steam oxidation process to form an adhesion layer on top of a sealing surface of the component. The adhesion layer is an oxidation layer that a thermal metal spray coating can be applied on top of in order to prevent spalling that can occur at high heat. Once the process is completed, the component can be inspected to ensure that it meets or exceeds the manufacturer's original specifications.

Abstract: A laser cladding system includes a laser apparatus, a chamber, and a pump system. The laser apparatus is configured to generate a laser beam. The chamber includes an interior surface that defines a cladding area comprising a sealed volume. The chamber includes a window that is made from a laser-transparent material and is configured to allow the laser beam to pass therethrough into the cladding area. The pump system has a port in communication with the cladding area. The pump system is configured to selectively generate a vacuum pressure within the cladding area sufficient to evacuate gas from within the cladding area out through the port. The laser apparatus includes a laser head from which the laser beam is emitted and a robotic laser motion system configured to selectively move the laser head such that the laser beam moves relative to a reference point within the chamber.

Abstract: A manufacturing process includes depositing a clad layer having a thickness greater than about 0.5 mm (0.02 in) on a surface of the component by hardfacing, and creating a heat affected zone directly below the clad layer due to the depositing. The heat affected zone may be a region of the component where a lowest hardness is lower than a base hardness of the component below the heat affected zone. The method may also include heat treating the component after the deposition such that the lowest hardness in the heat affected zone is restored to within about 15% of the base hardness of the component.

Abstract: Cladding and remanufacturing a machine component includes directing cleaning and welding beams split from an incident laser beam toward the machine component, and moving the machine component relative the cleaning and welding beams such that the welding beam trails behind the cleaning beam along a common travel path. A surface of the machine component is decontaminated by the cleaning beam, while a cladding material is melted via the welding beam such that upon solidifying the cladding material forms a coating metallurgically bonded to base material and previously deposited cladding material of the machine component.

Abstract: A process of remanufacturing a component such as an attachment flange used in turbochargers is provided and includes using a steam oxidation process to form an adhesion layer on top of a sealing surface of the component. The adhesion layer is an oxidation layer that a thermal metal spray coating can be applied on top of in order to prevent spalling that can occur at high heat. Once the process is completed, the component can be inspected to ensure that it meets or exceeds the manufacturer's original specifications.

Abstract: A valve for use in an internal combustion engine is disclosed. The valve includes a stem connected to a fillet disposed between the stem and a seat face. A thermal spray technique, such as a high velocity oxy fuel coating spray (HVOF) is applied to the seat face. A nitriding treatment that includes a nitrogen source, which may or may not contain carbon, and heat may be applied after the HVOF spray. The heat allows the nitrogen and/or carbon to penetrate the HVOF layer and the seat face to form a compound zone. The compound zone enhances the wear resistance of the surface during engine operation.

Abstract: A method of producing a mechanical face seal, the method including a step of obtaining a cast or wrought substrate part having an inner diameter, outer diameter, and a planar surface. The method may include a rough surface treatment step to form pores, peaks, and valleys on the planar surface of the substrate part. The method may further include a spraying step to supply a spray coating material onto the substrate part to form a protective thermal spray coating layer on the substrate part.

Abstract: A method of forming a layer of cladding material on a component includes performing a metal deposition process to deposit cladding material onto a surface of the component and onto a mold member. A metallurgical bond is formed between the cladding material and the component, but not between the cladding material and the mold member. The mold member may be removed after the metal deposition process, and the layer of cladding material can be processed to modify its shape.

Abstract: Cladding and remanufacturing a machine component includes directing cleaning and welding beams split from an incident laser beam toward the machine component, and moving the machine component relative the cleaning and welding beams such that the welding beam trails behind the cleaning beam along a common travel path. A surface of the machine component is decontaminated by the cleaning beam, whilst a cladding material is melted via the welding beam such that upon solidifying the cladding material forms a coating metallurgically bonded to base material and previously deposited cladding material of the machine component.

Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.

Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.

Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.

Abstract: An alloy including a Pt-group metal, Ni and Al, wherein the concentration of Al is limited with respect to the concentration of Ni and the Pt-group metal such that the alloy includes substantiailly no ?-NiAl phase, and wherein the Pt-group metal is present in an amount sufficient to provide enhanced hot corrosion resistance.

Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.

Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+?-Ni3Al phase constitution, and a coating including the alloy.