Abstract: A seal system, for an apparatus that includes a rotatable portion with airfoils coupled thereto and a stationary portion with an inner surface, includes an abradable portion including at least one abradable layer of an abradable material formed over the inner surface. The seal system also includes an abrading portion disposed over at least a portion of a substrate of the airfoil. The abrading portion includes at least one abrading layer formed on at least a portion of the substrate and a plurality of abrasive particles embedded within the abrading layer. The plurality of abrasive particles includes at least one of substantially all of one of tantalum carbide (TaC), aluminum oxide (Al2O3), and ziconia (ZrO2), cubic boron nitride (cBN) and Al2O3 in predetermined ratios, cBN, Al2O3 and ZrO2 in predetermined ratios, Al2O3 and ZrO2 fused together in predetermined ratios, and TaC and Al2O3 in predetermined ratios.

Abstract: The present invention provides a method of applying a coating to a perforated substrate, the method comprising: (a) providing a perforated substrate having a substrate first surface, a substrate second surface and one or more perforations traversing the substrate from the first surface to the second surface; (b) bringing the substrate first surface into contact with a perforation blocking solid; (c) applying a metallic thermal spray coating composition to the substrate second surface using a thermal spray technique; and (d) separating the perforation blocking solid from the substrate first surface to provide a substrate having a metallic thermal spray coating disposed upon the substrate second surface and wherein the perforations are not occluded by the metallic thermal spray coating. Among its many other uses, the method is also useful for applying thermal spray coatings to the interior surface of valve cages used in flow control valves.

Abstract: A component is disclosed. The component comprises a substrate comprising an outer surface and an inner surface, where the inner surface defines at least one hollow, interior space, where the outer surface defines one or more grooves, and where each of the one or more grooves extends at least partially along the surface of the substrate and has a base. One or more access holes extend through the base of a respective groove to place the groove in fluid communication with respective ones of the at least one hollow interior space. The component further comprises a coating disposed over at least a portion of the substrate surface, where the coating comprises one or more layers. At least one of the layers defines one or more permeable slots, such that the respective layer does not completely bridge each of the one or more grooves. The grooves and the coating together define one or more channels for cooling the component.

Abstract: A component is disclosed. The component comprises a substrate comprising an outer surface and an inner surface, where the inner surface defines at least one hollow, interior space, where the outer surface defines one or more grooves, and where each of the one or more grooves extends at least partially along the surface of the substrate and has a base. One or more access holes extend through the base of a respective groove to place the groove in fluid communication with respective ones of the at least one hollow interior space. The component further comprises a coating disposed over at least a portion of the substrate surface, where the coating comprises one or more layers. At least one of the layers defines one or more permeable slots, such that the respective layer does not completely bridge each of the one or more grooves. The grooves and the coating together define one or more channels for cooling the component. Methods for fabricating and coating a component are also provided.

Abstract: The present invention provides a method of protecting refinery equipment, the method comprising: (a) applying an uncured organic coating comprising a curable epoxy phenol novolac resin and a curing agent comprising a vicinal primary diamine moiety to a surface of refinery equipment susceptible to corrosion and/or wear; and (b) curing the uncured coating to form a cured coating having a viscosity of at least 2,000,000 centipoise; wherein the uncured organic coating has a viscosity of less than 500,000 centipoise, and wherein the uncured coating is substantially free of components comprising secondary and tertiary amine groups, and wherein the uncured coating is characterized by a latent viscosity of at least 2,000,000 when cured for 1 hour at 50° C.

Abstract: One aspect of the present invention includes a method. The method includes combusting a fuel and an oxidant in a combustion chamber of a thermal spray gun to form a combustion stream. The method further includes injecting a liquid and a feedstock material into the combustion stream in the combustion chamber to form an entrained feedstock stream, wherein the feedstock material includes a plurality of cermet particles having a median particle size of less than about 5 microns. The method further includes directing the entrained feedstock stream on a surface of a substrate to form a coating, wherein a temperature of the plurality of cermet particles in the entrained feedstock stream is less than a melting temperature of the plurality of cermet particles. Coated articles are also presented.

Abstract: The present disclosure is directed to the use and manufacture of cooling features within a component used in a hot gas path, such as within a turbine. In one embodiment, channels are formed within an external surface of the component and filled with a removable material. The external surface and channels may then be coated with one or more layers, such as a structural layer and/or top coat. The removable material may then be removed to leave the channels free of the removable material.

Abstract: A component is disclosed. The component comprises a substrate comprising an outer surface and an inner surface, where the inner surface defines at least one hollow, interior space, where the outer surface defines one or more grooves, and where each of the one or more grooves extends at least partially along the surface of the substrate and has a base. One or more access holes extend through the base of a respective groove to place the groove in fluid communication with respective ones of the at least one hollow interior space. The component further comprises a coating disposed over at least a portion of the substrate surface, where the coating comprises one or more layers. At least one of the layers defines one or more permeable slots, such that the respective layer does not completely bridge each of the one or more grooves. The grooves and the coating together define one or more channels for cooling the component. Methods for fabricating and coating a component are also provided.

Abstract: The present invention provides a method for preparing an electroless nickel coating composition that includes (a) coating a substrate with an electroless nickel coating to provide a coated substrate; and (b) subjecting the coated substrate to a heating protocol comprising heating to a temperature in a range from about 550° C. to about 700° C. for a period of from about 7 to about 30 hours. An article made from the method is also provided.

Abstract: The present invention provides methods for manufacturing an article having a wetting-resistant surface. The method includes providing a mixture comprising a plurality of micron-sized first particles and a plurality of nano-sized second particles, and a binder; depositing the mixture onto a substrate to form a wetting-resistant surface via a thermal spray process. The mixture is deposited without substantial melting of the first and second particles. The wetting-resistant surface has wettability sufficient to generate, with a reference fluid, a static contact angle of greater than about 90 degrees.

Abstract: The present invention provides a method for sealing pinholes in an electroless metal coating, said method comprising: (a) coating a substrate with an electroless metal coating layer to provide a coated article comprising an electroless metal coating in contact with the surface of the substrate, said electroless metal coating being characterized by the presence of pinhole imperfections which allow fluid communication between the substrate and the environment; (b) applying a layer of a curable epoxy sealant over the electroless metal coating layer and filling the pinhole imperfections; (c) curing the curable epoxy sealant to provide a cured epoxy overcoating layer; and (d) removing a substantial portion of the cured epoxy overcoating layer to provide an article comprising an electroless metal coating which is substantially free of pinhole imperfections allowing fluid communication between the substrate and the environment.

Abstract: There is provided a fuel rod assembly comprising a first component of a zirconium-based material. The first component is in contact with or is located adjacent to a second component of a material different from the zirconium-based material, e.g. a nickel-based or iron-based alloy. A coating is disposed on an outer surface of the first component, which is effective to reduce an electrochemical corrosion potential difference between the first component and the second component relative to an electrochemical corrosion potential difference between the first component and the second component without the coating.

Abstract: Process for roughening a surface of a base metal substrate includes contacting the surface with an aqueous solution comprising oxalic acid, sulfuric acid, and hydrogen peroxide at a temperature and for a period of time effective to roughen the surface to an average roughness greater than 60 Ra, removing a modest amount of base material, and generating no narrow and deep crevices at all. The surface is roughened prior to application of an electroless coating onto the substrate.

Abstract: Multiple layers of nickel phosphorous coatings are formed by electroless plating onto a base metal substrate such as a turbine component. In one embodiment, a first nickel layer metallurgical bonded by a heat treatment process to a surface of the base metal substrate, the first nickel layer containing about 4 to about 6 weight percent phosphorous with the balance being essentially nickel; and a second nickel layer deposited onto the first layer, the second nickel layer containing about 8 to about 12 weight percent phosphorous with the balance being essentially nickel, wherein the first and second layers are formed by electroless plating. In this manner, adhesion is maximized without degrading the properties of the second layer such as corrosion resistance and ductility. Also disclosed are processes for forming the multilayered nickel phosphorus coatings.

Abstract: A bearing assembly mounted in an x-ray tube includes a bearing race and a bearing ball positioned adjacent to the bearing race. A lubricant is deposited on a first portion of a bare metal of one of the bearing race and the bearing ball, and a metal matrix deposited on a second portion of the bare metal.

Abstract: A fuel rod includes a cladding tube with a wear-inhibiting coating. In one embodiment, the coating is made of a metallic powder material that is applied to the exterior surface of the cladding tube using a thermal spray process. In an alternative embodiment, the coating is a composite made of a metallic powder material, and a ceramic powder material or a metal oxide hard phase powder material that is simultaneously applied with the metallic powder material to coat the cladding tube. The coating can be applied to selected areas of the fuel rods where debris tends to fret the fuel rod.

Abstract: The present invention provides methods for manufacturing an article having a wetting-resistant surface. The method includes providing a mixture comprising a plurality of micron-sized first particles and a plurality of nano-sized second particles, and a binder; depositing the mixture onto a substrate to form a wetting-resistant surface via a thermal spray process. The mixture is deposited without substantial melting of the first and second particles. The wetting-resistant surface has wettability sufficient to generate, with a reference fluid, a static contact angle of greater than about 90 degrees.

Abstract: Erosion resistant coating processes and material improvements for line-of-sight applications. The erosion resistant coating composition includes nanostructured grains of tungsten carbide (WC) and/or submicron sized grains of WC embedded into a cobalt chromium (CoCr) binder matrix. A high velocity air fuel thermal spray process (HVAF) is used to create thick coatings in excess of about 500 microns with high percentages of primary carbide for longer life better erosion resistant coatings. These materials and processes are especially suited for hydroelectric turbine components.

Abstract: A bearing assembly mounted in an x-ray tube includes a bearing race and a bearing ball positioned adjacent to the bearing race. A coating is deposited on one of the bearing race and the bearing ball includes a lubricant and a hard material having a hardness greater than a base material of the bearing race and a base material of the bearing ball.

Abstract: A method of making a thermal spray powder is provided. The method comprises: providing a powder comprising a plurality of porous particles; infiltrating a mixture comprising a solvent and a plurality of solid lubricant particles into the porous particles; and heating the powder to a temperature sufficient to evaporate the solvent. The method of forming a wear-resistant coating is provided. The method comprises: providing a thermal spray powder; heating the thermal spray powder; and accelerating the thermal spray powder from a thermal spray gun onto the substrate, to form a deposit. Yet another embodiment provides a wear resistant coating. The wear resistant coating is formed by thermally spraying the thermal spray powder.