Abstract: A composition includes aluminum (Al), and a blend of a carbide and nickel-chromium (Ni-20Cr). The method of applying a coating composition includes blending a carbide and nickel-chromium (Ni-20Cr) with aluminum (Al) to form a composition, the carbide and the nickel-chromium (Ni-20Cr) in a range between 90% and about 99.5% by weight of the composition, and wherein the aluminum (Al) is in a range between about 0.5% and less than about 10% by weight of the composition; and spraying the composition on the turbine component.

Abstract: A high entropy ceramic (HEC) composition includes at least three different rare earth (RE) oxides and at least one of hafnium dioxide (HfO2) and zirconia oxide (ZrO2). The at least three different rare earth oxides being equimolar fractions. In one aspect, the high entropy ceramic (HEC) composition can be used in a thermal barrier coating.

Abstract: Various embodiments include a dense abradable coating, a method of reducing rub damage to a turbine engine part by applying the dense abradable coating thereto, and a turbine engine part having the abradable coating thereon. Particular embodiments include a dense abradable coating including a pore-free metallic composite, a high-aluminum containing brittle alloy, and a plurality of hollow abradable particles.

Abstract: Various embodiments include a dense abradable coating, a method of reducing rub damage to a turbine engine part by applying the dense abradable coating thereto, and a turbine engine part having the abradable coating thereon. Particular embodiments include a dense abradable coating including a pore-free metallic composite, a high-aluminum containing brittle alloy, and a plurality of hollow abradable particles.

Abstract: Various embodiments include honeycomb structures including an abradable material, and a method of applying such honeycomb structures to steel components of a gas turbine engine in order to reduce rub damage. Particular embodiments include a honeycomb structure having a plurality of cells, each cell of the plurality of cells including a cell wall surrounding a void, and an abradable material within the void of each cell of the plurality of cells, the abradable material including a metallic alloy and hollow particles.

Abstract: A system for coating a component is provided. The system includes a feedstock supply, a carrier fluid supply, and a thermal spray gun coupled in flow communication with the feedstock supply and the carrier fluid supply. The feedstock supply contains a substantially homogeneous powder mixture of a first powder and a second powder. The second powder is softer than the first powder and has a percentage by mass of the powder mixture of between about 0.1% and about 3.0%.

Abstract: A method for repairing a Ni-based alloy component includes preparing a surface of the Ni-based alloy component for receiving a cold spray repair; spraying a stream of particles onto a the surface of the Ni-based alloy component to form a coating thereon; and removing any over-spray on the surface of the Ni-based alloy component. The particles are formed from an alloy material having a melting point such that the particles are sprayed at a spray temperature that is less than the melting point of the alloy material.

Abstract: A method for repairing a Ni-based alloy component is prepared. The method may include preparing a surface of the Ni-based alloy component for receiving a cold spray repair; spraying a stream of particles onto a the surface of the Ni-based alloy component to form a coating thereon; and removing any over-spray on the surface of the Ni-based alloy component. The particles may be formed from an alloy material having a melting point such that the particles are sprayed at a spray temperature that is less than the melting point of the alloy material.

Abstract: A composition for a reinforced metal matrix coating, and a method of preparing and coating the composition. The composition includes a plurality of sacrificial metallic binder particles that is anodic with respect to a base substrate, and a plurality of hard particles.

Abstract: A gas turbine process includes supplying a fuel to a gas turbine, combusting the fuel in the gas turbine with a hot gas path temperature reaching at least 1100° C. during operation of the gas turbine, and supplying an inhibition composition including at least one yttrium-containing inorganic compound to interact with the vanadium and inhibit vanadium hot corrosion in the gas turbine caused by vanadium as a fuel impurity in the fuel. A process includes supplying an inhibition composition including at least one yttrium-containing inorganic compound to a hot gas path or a combustor of a gas turbine. A fuel composition includes a fuel including at least one fuel impurity including vanadium and an inhibition composition including at least one yttrium-containing compound. An atomic ratio of yttrium to vanadium in the fuel composition is in a range of 1 to 1.5.

Abstract: A system for coating a component is provided. The system includes a feedstock supply, a carrier fluid supply, and a thermal spray gun coupled in flow communication with the feedstock supply and the carrier fluid supply. The feedstock supply contains a substantially homogeneous powder mixture of a first powder and a second powder. The second powder is softer than the first powder and has a percentage by mass of the powder mixture of between about 0.1% and about 3.0%.

Abstract: A method for joining a ceramic component to a metallic component is described. At least one layer of molybdenum is applied to a surface of the ceramic component, by a high-velocity molybdenum wire spray technique. A layer of a nickel-based braze composition is then applied over the molybdenum layer. The braze composition and the ceramic and metallic components are then heated to a sufficient brazing temperature, so as to provide a braze joint between the components. The method can be used to seal an open region of a thermal battery, e.g., a sodium metal halide-based battery.

Abstract: A method for joining a ceramic component to a metallic component is described. At least one initial layer of an active metal is applied to one of the joining surfaces, by a cold spray technique. At least one second layer of a nickel-based braze composition is then applied over the initial layer by cold-spraying. The braze composition and components are then heated, so as to form an active braze joint between them. A method of sealing an open region of a sodium metal halide-based battery is also disclosed, using the brazing technique described herein to form braze joints that seal various components in the battery cells, such as metallic rings and ceramic collar structures.

Abstract: A method for joining a ceramic component to a metallic component is described. At least one initial layer of an active metal is applied to one of the joining surfaces, by a cold spray technique. At least one second layer of a nickel-based braze composition is then applied over the initial layer by cold-spraying. The braze composition and components are then heated, so as to form an active braze joint between them. A method of sealing an open region of a sodium metal halide-based battery is also disclosed, using the brazing technique described herein to form braze joints that seal various components in the battery cells, such as metallic rings and ceramic collar structures.

Abstract: A process of fabricating a thermal barrier coating is disclosed. The process includes cold spraying a substrate with a feedstock to form a thermal barrier coating and concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating. The cold spraying is in a region having an oxygen concentration of at least 10%. In another embodiment, the process includes heating a feedstock with a laser and cold spraying a substrate with the feedstock to form a thermal barrier coating. At least a portion of the feedstock is retained in the thermal barrier coating. In another embodiment, the process of fabricating a thermal barrier coating includes heating a substrate with a laser and cold spraying the substrate with a feedstock to form a thermal barrier coating.

Abstract: A coated article and a method for producing a coating are disclosed. The method for producing a coating includes providing an iron-based alloy substrate, and depositing a protective coating over a surface of the iron-based alloy substrate. The protective coating includes a cobalt-chromium-based coating material having at least one anodic element distributed therein. The at least one anodic element being anodic to the iron-based alloy substrate. Another method for producing a coating includes providing an iron-based alloy substrate, depositing an underlayer including at least one anodic element over a surface of the iron-based alloy substrate, and depositing a top coat including a cobalt-chromium-based coating material over the underlayer. The at least one anodic element being anodic to the iron-based alloy substrate. The coated article includes a protective coating having at least one anodic element distributed therein deposited over a surface of an iron-based alloy substrate.

Abstract: A composition for a reinforced metal matrix coating, and a method of preparing and coating the composition. The composition includes a plurality of sacrificial metallic binder particles that is anodic with respect to a base substrate, and a plurality of hard particles.

Abstract: A method of repairing a damaged rotor comprising: (a) preparing a locally damaged portion of the rotor; (b) cold spraying alloy powder particles onto the locally damaged portion; (c) controlling the cold spraying in step (b) to restore the locally damaged portion to form a repaired portion having substantially the same properties and shape as originally manufactured; and (d) heat treating at least the repaired portion.

Abstract: A coating composition, a process of applying a coating having a coating composition, and a process of forming a coating composition are disclosed. The coating composition includes an alloy and an oxide component comprising nickel oxide. The process of applying the coating includes cold spraying the coating onto the article. The process of forming the coating composition includes blending and milling the alloy with the oxide component.

Abstract: A plated component and a plating process are disclosed. The plating process includes applying a material to a region of a component, the material being selected from the group consisting of nickel, cobalt, chromium, iron, aluminum, or a combination thereof. The region includes a single crystal microstructure, includes a directionally solidified microstructure, is substantially devoid of equiaxed microstructure, or a combination thereof. The applying includes electroplating, electroless plating, or the electroplating and the electroless plating. The plated component includes an electroplated region, an intermediate layer on the electroplated region, and an overlay coating on the intermediate layer.