Abstract: Methods of fabricating coated components using multiple types of fillers are provided. One method comprises forming one or more grooves in an outer surface of a substrate. Each groove has a base and extends at least partially along the outer surface. A sacrificial filler is deposited within the groove, a second filler is deposited over the sacrificial filler, and a coating is disposed over at least a portion of the outer surface and over the second filler. The method further includes removing the sacrificial filler and at least partially removing the second filler from the groove(s), to define one or more channels for cooling the component.

Abstract: A method of fabricating a component is provided. The method includes depositing a structural coating on an outer surface of a substrate, where the substrate has at least one hollow interior space. The method further includes forming one or more grooves in the structural coating. Each groove has a base and extends at least partially along the substrate. The method further includes depositing at least one additional coating over the structural coating and over the groove(s), such that the groove(s) and the additional coating together define one or more channels for cooling the component. The method further includes forming one or more access holes through the base of a respective groove, to connect the respective groove in fluid communication with the respective hollow interior space, and forming at least one exit hole through the additional coating for each channel, to receive and discharge coolant from the respective channel. A component with cooling channels formed in a structural coating is also provided.

Abstract: The present invention provides a method of making a flanged metal article. The method comprises (a) applying a first braze compound to a first portion of a metal article; (b) winding the first portion of a metal article with a length of a constraining metal member; and (c) heating an assembly of the metal article, the constraining metal member, and the first braze compound to a temperature above the solidus temperature of the first braze compound, typically a temperature in a range from about 300° C. to about 2500° C., to provide a flanged metal article, wherein the metal article has a coefficient of thermal expansion CTE 1, the constraining metal member has a coefficient of thermal expansion CTE 2, and CTE 1 is greater than CTE 2. The invention further provides a metal flange, which minimizes thermal expansion mismatch between a high expansion metal and a low expansion brittle material.

Abstract: A method of sealing a ceramic component to a metal component for a metal halide battery is provided. The method involves the steps of coating a portion of the ceramic component with a metallic coating, and then bonding the coated ceramic component to the metal component. The metallic coating includes a reactive metal. A sealing structure formed by using such a method is also presented.

Abstract: A method of fabricating a component is provided. The fabrication method includes depositing a first layer of a structural coating on an outer surface of a substrate. The substrate has at least one hollow interior space. The fabrication method further includes machining the substrate through the first layer of the structural coating, to define one or more openings in the first layer of the structural coating and to form respective one or more grooves in the outer surface of the substrate. Each groove has a respective base and extends at least partially along the surface of the substrate. The fabrication method further includes depositing a second layer of the structural coating over the first layer of the structural coating and over the groove(s), such that the groove(s) and the second layer of the structural coating together define one or more channels for cooling the component. A component is also disclosed.

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: A method of fabricating a component is provided. The method includes depositing a fugitive coating on a surface of a substrate, where the substrate has at least one hollow interior space. The method further includes machining the substrate through the fugitive coating to form one or more grooves in the surface of the substrate. Each of the one or more grooves has a base and extends at least partially along the surface of the substrate. The method further includes forming one or more access holes through the base of a respective one of the one or more grooves to connect the respective groove in fluid communication with the respective hollow interior space. The method further includes filling the one or more grooves with a filler, removing the fugitive coating, disposing a coating over at least a portion of the surface of the substrate, and removing the filler from the one or more grooves, such that the one or more grooves and the coating together define a number of channels for cooling the component.

Abstract: A method of recovering rhenium from rhenium-containing superalloy scrap is provided. The superalloy is usually a nickel-based superalloy. The method includes the steps of forming an oxidation feedstock of flaky morphology of the superalloy scrap, and oxidizing the oxidation feedstock to convert rhenium into a volatile rhenium oxide. The flaky morphology of the oxidation feedstock is achieved by increasing the surface area of the superalloy scrap.

Abstract: A sensor system, and an associated method for detecting harsh environmental conditions, is provided. The sensor system includes at least one sensor having an electrical sensing element. The electrical sensing element is based on certain classes of composite materials: (a) silicon carbide (SiC); (Mo,W)5Si3C; (Mo,W)Si2; or (b) (Mo,W)5Si3C; (Mo,W)Si2; (Mo,W)5Si3. The sensor system is useful for determining harsh environmental conditions. Gasification systems, which include at least one of the sensor systems are also described.

Abstract: A method for forming a nickel aluminide based coating on a metallic substrate includes providing a first source for providing a significant portion of the aluminum content for a coating precursor and a separate nickel alloy source for providing substantially all the nickel and additional alloying elements for the coating precursor. Cathodic arc (ion plasma) deposition techniques may be utilized to provide the coating precursor on a metallic substrate. The coating precursor may be provided in discrete layers, or from a co-deposition process. Subsequent processing or heat treatment forms the nickel aluminide based coating from the coating precursor.

Abstract: A method for forming a nickel aluminide based coating on a metallic substrate includes providing a first source for providing a significant portion of the aluminum content for a coating precursor and a separate nickel alloy source for providing substantially all the nickel and additional alloying elements for the coating precursor. Cathodic arc (ion plasma) deposition techniques may be utilized to provide the coating precursor on a metallic substrate. The coating precursor may be provided in discrete layers, or from a co-deposition process. Subsequent processing or heat treatment forms the nickel aluminide based coating from the coating precursor.

Abstract: A method of recovering rhenium from rhenium-containing superalloy scrap is provided. The superalloy is usually a nickel-based superalloy. The method includes the steps of forming an oxidation feedstock of flaky morphology of the superalloy scrap, and oxidizing the oxidation feedstock to convert rhenium into a volatile rhenium oxide. The flaky morphology of the oxidation feedstock is achieved by increasing the surface area of the superalloy scrap.

Abstract: A target assembly for generating x-rays includes a target substrate, and an emissive coating applied to a portion of the target substrate, the emissive coating comprising one or more of a carbide and a carbonitride.

Abstract: A target assembly for generating x-rays includes a target substrate, and an emissive coating applied to a portion of the target substrate, the emissive coating comprising one or more of a carbide and a carbonitride.

Abstract: Disclosed herein is a turbine component comprising a substrate; and a protective structure formed on the substrate, wherein the protective structure comprises an ?-? titanium alloy, a ?-titanium alloy or a near-? titanium alloy. Disclosed herein too is a process for providing a protective structure to a turbine component, comprising affixing a protective structure on a turbine component; wherein the protective structure comprises an ?-? titanium alloy, a near-? titanium alloy or a ?-titanium alloy.

Abstract: An erosion resistant protective structure for a turbine engine component comprises a shape memory alloy. The shape memory alloy includes nickel-titanium based alloys, indium-titanium based alloys, nickel-aluminum based alloys, nickel-gallium based alloys, copper based alloys, gold-cadmium based alloys, iron-platinum based alloys, iron-palladium based alloys, silver-cadmium based alloys, indium-cadmium based alloys, manganese-copper based alloys, ruthenium-niobium based alloys, ruthenium-tantalum based alloys, titanium based alloys, iron-based alloys, or combinations comprising at least one of the foregoing alloys. Also, disclosed herein are methods for forming the shape memory alloy onto turbine component.

Abstract: A coated article, a coating for protecting an article, and a method for protecting an article are provided. The article comprises a metallic substrate and a substantially single-phase coating disposed on the substrate, wherein the coating comprises nickel (Ni) and at least about 30 atomic percent aluminum (Al); the coating further comprises a gradient in Al composition, the gradient extending from a first Al concentration level at an outer surface of the coating to a second Al concentration level at an interface between the substantially single-phase coating and the substrate, wherein the first Al concentration level is greater than the second Al concentration level and the second concentration level is at least about 30 atomic percent Al.

Abstract: Process of brazing an alumina-coated honeycomb and fiber metal material to a substrate, in which a mask material is applied to a portion of the honeycomb and fiber metal prior to deposition of the Al2O3, and the mask material is removed after deposition and prior to brazing to the substrate.

Abstract: Oxidation resistant sealant system comprising a honeycomb component coated with an aluminum oxide layer.