Abstract: Coated articles adapted to be subjected to direct and sustained mechanical contact are provided. The coated articles include a ceramic matrix composite (CMC) substrate. A solid coating is disposed directly on and adheres to the substrate during such direct and sustained mechanical contact. The solid coating is formed from a precursor comprising a liquid binder, which may be sodium silicate, a basic colloidal alumina solution, aluminum hydroxide, aluminum oxychloride, aluminum hydroxylchloride, aluminum phosphate, and phosphoric acid. The coating may also include a filler material such as solid powder, chopped fibers, and combinations thereof. Methods for improving the wear resistance of an article made from the CMC substrates are also provided. A CMC substrate is provided and covered with a slurry. The slurry includes the liquid binder and optionally, the filler material. The slurry is consolidated, for example, by annealing to form a wear-resistant solid coating on the article.

Abstract: Embodiments of a lightweight, high temperature airborne valve are provided. In one embodiment, the airborne vale includes a valve element and a flowbody. The flowbody is formed at least partially from a titanium aluminide alloy and has a flow passage therethrough in which the valve element is movably mounted. Embodiments of a method for producing such a lightweight, high temperature airborne valve are also provided. In one embodiment, the method includes the steps of forming a lightweight flowbody at least partially from a titanium aluminide alloy, hot isostatically pressing the lightweight flowbody, and machining the lightweight flowbody to desired dimensions.

Abstract: The present invention provides panels for a microchannel heat exchanger core wherein the panels may have greater than about 36 fins per inch of the panel. The microchannels of the panels may have an aspect ratio of at least about 10. Panels are also provided having microchannels and fins on one side of the panel or on opposite sides of the panel. Methods are also provided for machining the panels of the present invention.

Abstract: Coated articles adapted to be subjected to direct and sustained mechanical contact are provided. The coated articles include a ceramic matrix composite (CMC) substrate. A solid coating is disposed directly on and adheres to the substrate during such direct and sustained mechanical contact. The solid coating is formed from a precursor comprising a liquid binder, which may be sodium silicate, a basic colloidal alumina solution, aluminum hydroxide, aluminum oxychloride, aluminum hydroxylchloride, aluminum phosphate, and phosphoric acid. The coating may also include a filler material such as solid powder, chopped fibers, and combinations thereof. Methods for improving the wear resistance of an article made from the CMC substrates are also provided. A CMC substrate is provided and covered with a slurry. The slurry includes the liquid binder and optionally, the filler material. The slurry is consolidated, for example, by annealing to form a wear-resistant solid coating on the article.

Abstract: Methods of densifying a complex-shaped and/or asymmetrical porous structure include providing a porous structure having such shape, connecting at least two regions of the porous structure with an electrically-conductive element to form a continuous electrically-conductive assembly to enable non-contact electromagnetic coupling between the porous structure and an induction coil, establishing a thermal gradient from an inner region of the porous structure to an outer surface region thereof, where the inner region is at a temperature that is initially higher than a temperature of the outer surface region and that causes decomposition of a compound to effect deposition of a solid derived from the decomposition of the compound on and within the inner porous region, exposing the porous structure to the gaseous compound to effect deposition of the solid within the porous structure, and continuing the steps of establishing and exposing until the porous structure has a predetermined mass or density.

Abstract: Embodiments of a lightweight, high temperature airborne valve are provided. In one embodiment, the airborne vale includes a valve element and a flowbody. The flowbody is formed at least partially from a titanium aluminide alloy and has a flow passage therethrough in which the valve element is movably mounted. Embodiments of a method for producing such a lightweight, high temperature airborne valve are also provided. In one embodiment, the method includes the steps of forming a lightweight flowbody at least partially from a titanium aluminide alloy, hot isostatically pressing the lightweight flowbody, and machining the lightweight flowbody to desired dimensions.

Abstract: A stator vane is provided that includes an airfoil and a coating. The airfoil comprises a polymer matrix fiber composite having a melting point, glass transition temperature, or maximum exposure temperature that is less than about 150° C. The coating is formed over the airfoil and comprises a material that is more erosion-resistant than the polymer matrix fiber composite, where the material is the selected from a group of constituents consisting of titanium, chromium, vanadium, and zirconium, and nitrides, carbides, mixed carbonitrides, oxides, oxynitrides, oxycarbides, and oxycarbonitrides thereof. Methods for making the stator vane are provided as well.

Abstract: The invention concerns a method for applying a surface modification agent composition for organosilicate glass dielectric films. More particularly, the invention pertains to a method for treating a silicate or organosilicate dielectric film on a substrate, which film either comprises silanol moieties or has had at least some previously present carbon containing moieties removed therefrom. The treatment adds carbon containing moieties to the film and/or seals surface pores of the film, when the film is porous.

Abstract: The present invention provides panels for a microchannel heat exchanger core wherein the panels may have greater than about 36 fins per inch of the panel. The microchannels of the panels may have an aspect ratio of at least about 10. Panels are also provided having microchannels and fins on one side of the panel or on opposite sides of the panel. Methods are also provided for machining the panels of the present invention.

Abstract: Components made from solid fiber inorganic-organic-polymer matrix composites and methods of making the components and composites are provided. In one embodiment, and by way of example only, the method includes the steps of impregnating a fiber preform with a liquid resin comprising at least one compound selected from the group consisting of silsesquioxane and polysilazane, and heating the resin-impregnated preform at a temperature below the resin pyrolysis temperature to form the solid fiber inorganic-organic-polymer matrix composite. In other embodiments, a component, such as a mechanical or an aircraft component is provided that includes a solid fiber inorganic-organic-polymer matrix composite. The solid fiber inorganic-organic-polymer matrix composite may include a fiber preform impregnated with a resin comprising at least one silsesquioxane or a fiber preform impregnated with a resin comprising at least one polysilazane.

Abstract: A stator vane is provided that includes an airfoil and a coating. The airfoil comprises a polymer matrix fiber composite having a melting point, glass transition temperature, or maximum exposure temperature that is less than about 150° C. The coating is formed over the airfoil and comprises a material that is more erosion-resistant than the polymer matrix fiber composite, where the material is the selected from a group of constituents consisting of titanium, chromium, vanadium, and zirconium, and nitrides, carbides, mixed carbonitrides, oxides, oxynitrides, oxycarbides, and oxycarbonitrides thereof. Methods for making the stator vane are provided as well.

Abstract: Coated articles (19) that comprise components, made of carbon fiber or carbon-carbon composites which may be configured, for example, as aircraft landing system brake discs. The components (10) are coated with a system that includes a phosphorus-containing undercoating (11) having a specified formulation and a boron-containing overcoating (12) having specified characteristics. The coated articles of the invention, e.g., aircraft brake discs, are protected against catalytic oxidation when the article is subjected to temperatures of 800° C. (1472° F.) or greater. Also, a method of protecting a component made of a carbon fiber or carbon-carbon composite simultaneously against catalytic oxidation (e.g., catalyzed by de-icer compositions) and high temperature non-catalytic oxidation.

Abstract: The invention concerns a method for applying a surface modification agent composition for organosilicate glass dielectric films. More particularly, the invention pertains to a method for treating a silicate or organosilicate dielectric film on a substrate, which film either comprises silanol moieties or has had at least some previously present carbon containing moieties removed therefrom. The treatment adds carbon containing moieties to the film and/or seals surface pores of the film, when the film is porous.

Abstract: The present invention provides panels for a microchannel heat exchanger core wherein the panels may have greater than about 36 fins per inch of the panel. The microchannels of the panels may have an aspect ratio of at least about 10. Panels are also provided having microchannels and fins on one side of the panel or on opposite sides of the panel. Methods are also provided for machining the panels of the present invention.

Abstract: Coated articles (19) that comprise components, made of carbon fiber or carbon-carbon composites which may be configured, for example, as aircraft landing system brake discs. The components (10) are coated with a system that includes a phosphorus-containing undercoating (11) having a specified formulation and a boron-containing overcoating (12) having specified characteristics. The coated articles of the invention, e.g., aircraft brake discs, are protected against catalytic oxidation when the article is subjected to temperatures of 800° C. (1472° F.) or greater. Also, a method of protecting a component made of a carbon fiber or carbon-carbon composite simultaneously against catalytic oxidation (e.g., catalyzed by de-icer compositions) and high temperature non-catalytic oxidation.

Abstract: Carbon composite components (1, 11, 22, 30), which may be aircraft brake discs, heat exchanger cores, and so on, are covered by protective coating 32. Component (1, 11, 22, 30) is immersed in liquid bath precursor of fluidized glass (step 55). After immersion step, glass-coated component (1, 11, 22, 30) is removed and annealed. Heat treatment gradually increases temperature to 250-350° C. at the rate of 1-2° C. per minute (step 60). Heat treatment is followed by soak at temperature of 250-350° C. for 1-10 hours (step 65). Temperature is then increased to 550-650° C. (step 70). Temperature is maintained at 550-650° C. for 1-10 hours (step 75). After completion of second prolonged heat treatment, the component is cooled until reaching room temperature (step 80). Upon completion of the annealing step, the fluidized glass coating converts to solid glass coating (32) enveloping and forming a protective barrier against undesirable oxidation of the C—C component (1, 11, 22, 30).

Abstract: A protective coating for a carbon-containing component comprises a material selected from the group consisting of non-stoichiometric silicon and carbon; non-stoichiometric silicon and oxygen; non-stoichiometric silicon and nitrogen; compounds of silicon, oxygen, and carbon; compounds of silicon, oxygen and nitrogen; compounds of silicon, nitrogen, and carbon; and silicon.

Abstract: Coated articles (19) that comprise components, made of carbon fiber or carbon-carbon composites which may be configured, for example, as aircraft landing system brake discs. The components (10) are coated with a system that includes a phosphorus-containing undercoating (11) having a specified formulation and a boron-containing overcoating (12) having specified formulation. The coated articles of the invention, e.g., aircraft brake discs, are protected against catalytic oxidation when the article is subjected to temperatures of 800° C. (1472° F.) or greater. Also, a method of protecting a component made of a carbon fiber or carbon-carbon composite simultaneously against catalytic oxidation (e.g., catalyzed by de-icer compositions) and high temperature non-catalytic oxidation.

Abstract: Fiber spinning of two polymer compositions wherein one of the compositions contains carbon nanotubes produces structures such as fibers, ribbons, yarns and films of carbon nanotubes. The polymers are removed and stabilization of the carbon nanotube material is achieved by post-spinning processes. The advances disclosed herein enable the carbon nanotube composites to be used in actuators, supercapacitors, friction materials and in devices for electrical energy harvesting.

Abstract: Complex features and fine details in a Carbon—Carbon work piece, for example, are formed by electrical discharge machining (EDM). An electrode used in the EDM is made of a material that is mechanically and chemically compatible with Carbon—Carbon composite material.