Abstract: A method is disclosed, which can comprise via a transonic gas jet, depositing a thin film of LiPON on a substrate via a directed vapor deposition process. The transonic gas jet transports a thermally evaporated vapor cloud comprising the LiPON, wherein, the transonic gas jet comprises one of (a) substantially entirely nitrogen (N2) gas; or (b) nitrogen (N2) gas as a dopant in a concentration greater than 10% by volume in an inert carrier gas.

Abstract: Certain exemplary embodiments can provide a method, which can comprise stabilizing adherence of a ceramic layer to a bond coat of a thermal barrier coating system, via incorporation of iron and cobalt into the bond coat at a given level. The bond coat can comprise MCrAlY, wherein M is selected from the group consisting of nickel, cobalt, iron and mixtures thereof.

Abstract: The present inventions incorporate self-healing mechanisms into current and future EBC systems. Such approaches have the potential to form environmental protection materials (i.e. thermally grown silicate compositions) in-situ to enable the ability to provide environmental protection to SiC based ceramics even in the event that cracks or voids form from within the EBC layer. In this disclosure, novel, self-healing EBC systems are disclosed along with coating synthesis techniques required to deposit the materials, microstructures and architectures. This research is anticipated to result in a thermal/environmental barrier coating system (T/EBC) that provides improved durability over current coatings. These advancements will aid the use of Si-based ceramics in a range of high temperature applications such a gas turbine engines and heat exchangers. These advances will not only benefit military engines, but also commercial and industrial engines requiring greater performance.

Abstract: Certain exemplary embodiments can provide a method, which can comprise via a transonic gas jet, depositing a thin film of LiPON on a substrate via a directed vapor deposition process. The transonic gas jet transports a thermally evaporated vapor cloud comprising the LiPON, wherein, the transonic gas jet comprises one of (a) substantially entirely nitrogen (N2) gas; or (b) nitrogen (N2) gas as a dopant in a concentration greater than 10% by volume in an inert carrier gas.

Abstract: Certain exemplary embodiments can provide a system, which can comprise an ultra-thin polymer ceramic composite separator. The ultra-thin polymer ceramic composite separator can comprise Li-ion conducting ceramic material. The ceramic composite separator has a columnar grained microstructure. The ultra-thin polymer ceramic composite separator can comprise a single or bi-layer combination of LiPON, LATP, garnets, lithium sulfides, or Li1+2xZr2?zCa(PO4)3.

Abstract: Certain exemplary embodiments can provide a system, which can comprise depositing a filament and a vapor flux that emanates from one or more vapor sources. The vapor flux is directed toward the filament via a carrier gas in a coating chamber under vacuum. The carrier gas can substantially surround the vapor flux as the filament is exposed to a coating material comprised by the vapor flux. Wherein the filament moves relative to the vapor flux.

Abstract: Certain exemplary embodiments can provide a method, which can comprise depositing a substantially uniform coating on a substrate. The coating is deposited via a coating material stream that emanates from one or more vapor sources. The coating material stream is directed toward the substrate via a carrier gas in a chamber under vacuum.

Abstract: Certain exemplary embodiments can provide a method, which can comprise depositing a coating on a substrate. The coating can be deposited via a plurality of plasma source units directed toward a carrier gas. The carrier gas can comprise a coating material from a source vapor. The coating material can be directed toward the substrate via the carrier gas in a chamber under vacuum.

Abstract: The present inventions incorporate self-healing mechanisms into current and future EBC systems. Such approaches have the potential to form environmental protection materials (i.e. thermally grown silicate compositions) in-situ to enable the ability to provide environmental protection to SiC based ceramics even in the event that cracks or voids form from within the EBC layer. In this disclosure, novel, self-healing EBC systems are disclosed along with coating synthesis techniques required to deposit the materials, microstructures and architectures. This research is anticipated to result in a thermal/environmental barrier coating system (T/EBC) that provides improved durability over current coatings. These advancements will aid the use of Si-based ceramics in a range of high temperature applications such a gas turbine engines and heat exchangers. These advances will not only benefit military engines, but also commercial and industrial engines requiring greater performance.

Abstract: The present invention provides a process for the application of high temperature coating that provide enhanced impact resistance and erosion damage for the coatings. For high temperature coating systems that provide environmental protection to silicon based ceramics, the process provides the deposition of a silicon-based bond coat on the substrate using the directed vapor deposition with plasma activation and at least one supersonic gas jet nozzle. The process provides the deposition of an EBC layer using the directed vapor deposition with the gas jet nozzle. In one embodiment, the thermal barrier layer may also contain one or more dense embedded layers which further promote impact resistance. Within the process, the particular layers, silicon bond coat, EBC layer and/or TBC layer may be deposited together or specific novel layers applied in combination with other layers deposited using prior known deposition techniques.

Abstract: A direct vapor deposition (DVD) apparatus and method is taught, that provides a carrier gas flow entraining vapor atoms for the coating of regions on a substrate that are not in line-of-sight. The degree of non line-of-sight (NLOS) coating, hence thickness uniformity around the substrate is a sensitive function of the flow conditions. For a fixed background pressure in the region of deposition, an increase in the uniformity of the coating thickness is accomplished as the flow velocity is reduced. This improvement in uniformity is a result of an increase in the fraction of vapor atoms which deposit in NLOS positions on the substrate such as backside (21) of fiber (65) as indicated by vapor streamlines (51). Vapor impact width (VIW) is the width of the vapor flux impacting on some area of the fiber. Front side coating (FSC) width is the vapor width of atoms impacting on the substrate frontside (22).

Abstract: A directed vapor deposition (DVD) method and system for applying at least one bond coating on at least one substrate for thermal barrier coating systems. To overcome the limitations incurred by conventional methods, the DVD system uses an electron beam directed vapor deposition (DVD) technique to evaporate and deposit compositionally and morphologically controlled bond coats at high rate. The present DVD system uses the combination of an electron beam and a combined inert gas/reactive gas carrier jet of controlled composition to create engineering films. In this system, the vaporized material can be entrained in the carrier gas jet and deposited onto the substrate at a high rate and with high materials utilization efficiency. The velocity and flux of the gas atoms entering the chamber, the nozzle parameters, and the operating chamber pressure can all be significantly varied, facilitating wide processing condition variation and allowing for improved control over the properties of the deposited layer.