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: A method of coating a surface, preparing a doped metal-ion precursor solution for coating, and an article including a component coated by the described method are disclosed. The method of coating includes applying a fluoro-silane doped metal-ion precursor solution on the surface to form a coated surface. The metal-ion precursor solution includes greater than about 0.6 molar percent concentration of a metal-ion precursor in a solvent comprising an alcohol. The method of preparing the doped metal-ion precursor solution includes dissolving a metal-ion precursor in a solvent comprising an alcohol at a temperature greater than about 100° C. and refluxing at a temperature greater than about 150° C. such that the concentration of metal-ion precursor in the solution is greater than 0.6 molar percent of the solution, and adding a fluoro-silane to the metal-ion precursor solution.

Abstract: Articles coated via a plasma spray process, and methods for making such articles, are presented. For example, one embodiment is an article comprising a substrate comprising a top surface and a channel disposed in the substrate. The channel is defined by an internal channel surface disposed beneath the top surface and having a terminal end at an orifice at the top surface. A coating is disposed on the top surface and on at least a portion of the internal channel surface. A coating thickness at any point on the internal channel surface is less than a nominal coating thickness on the top surface, and the coating comprises a plurality of at least partially melted and solidified particles.

Abstract: A method of processing a ceramic layer is provided. The method comprises the steps of providing a ceramic layer comprising a plurality of microcracks; infiltrating at least some of the plurality of microcracks with a liquid precursor comprising at least one oxidizable metal ion; and exposing the ceramic layer to a base having a pH value of at least about 9, so as to chemically convert the oxidizable metal ion into an oxide, thereby decreasing the porosity of the ceramic layer. A solid oxide fuel cell is provided. The solid oxide fuel cell comprises an anode; a cathode; and a ceramic electrolyte disposed between the anode and the cathode.

Abstract: An article coated with a highly durable, wetting resistant coating is provided. The article comprises a coating that comprises a cermet material. The cermet material includes a nickel-bearing metal matrix and a phase disposed within the matrix. The phase includes an anion moiety, for example nitrogen, carbon, or boron; and a cation moiety, for example chromium, zirconium, titanium, vanadium, hafnium, niobium, or tantalum. The phase is present in the cermet at a level of at least about 5 volume %.

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials. The oxide materials described herein as a class typically contain one or more of ytterbia (Yb2O3) and europia (Eu2O3). The oxides may further contain other additives, such as oxides of gadolinium (Gd), samarium (Sm), dysprosium (Dy), or terbium (Tb). In certain embodiments the oxide, in addition to the ytterbia and/or europia, further comprises lanthanum (La), praseodymium (Pr), or neodymium (Nd).

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials, methods for making these articles and materials, and methods for protecting articles using coatings made from these materials. One particular embodiment is an article that comprises a coating having a surface connected porosity content of up to about 5 percent by volume. The coating comprises a material that comprises a primary oxide and a secondary oxide, wherein (i) the primary oxide comprises a cerium cation, and (ii) the secondary oxide comprises a cation selected from the group consisting of the praseodymium and neodymium. The material is transparent to electromagnetic radiation of at least one type selected from the group consisting of ultraviolet radiation, visible light, and infrared radiation.

Abstract: Articles coated via a plasma spray process, and methods for making such articles, are presented. For example, one embodiment is an article comprising a substrate comprising a top surface and a channel disposed in the substrate. The channel is defined by an internal channel surface disposed beneath the top surface and having a terminal end at an orifice at the top surface. A coating is disposed on the top surface and on at least a portion of the internal channel surface. A coating thickness at any point on the internal channel surface is less than a nominal coating thickness on the top surface, and the coating comprises a plurality of at least partially melted and solidified particles.

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials. The oxide materials described herein as a class typically contain europia (Eu2O3). The oxides may further contain other additives, such as oxides of gadolinium (Gd), samarium (Sm), dysprosium (Dy), or terbium (Tb). In certain embodiments the oxide, in addition to europia, further comprises ytterbia (Yb2O3), lanthanum (La), praseodymium (Pr), or neodymium (Nd).

Abstract: In some embodiments, the present invention is directed to methods of making structures with complex functional architectures, where such structures generally comprise at least two mesoporous regions comprising different chemical activity, and where such methods afford spatial control over the placement of such regions of differing chemical activity. In some embodiments, the present invention is also directed to the structures formed by such methods, where such structures are themselves novel.

Abstract: A method and system for monitoring creep in a moving object are provided. The creep monitoring system includes a creep sensor assembly formed onto a surface of an object rotatable about an axis, the creep sensor assembly includes at least one of an image pattern and a radio frequency interrogatable circuit. The creep monitoring system also includes an online monitoring system communicatively coupled to the creep sensor assembly. The online monitoring system configured to collect information from the creep sensor assembly relative to an amount and a rate of creep of the object. The creep monitoring system also includes a processor programmed to receive the information, correct the information for movement of the creep sensor assembly during the collection, and determine a creep rate, a crack presence, and a temperature of the object simultaneously.

Abstract: Articles coated via a plasma spray process, and methods for making such articles, are presented. For example, one embodiment is an article comprising a substrate comprising a top surface and a channel disposed in the substrate. The channel is defined by an internal channel surface disposed beneath the top surface and having a terminal end at an orifice at the top surface. A coating is disposed on the top surface and on at least a portion of the internal channel surface. A coating thickness at any point on the internal channel surface is less than a nominal coating thickness on the top surface, and the coating comprises a plurality of at least partially melted and solidified particles.

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials. The oxide materials described herein as a class typically contain one or more of ytterbia (Yb2O3) and europia (Eu2O3). The oxides may further contain other additives, such as oxides of gadolinium (Gd), samarium (Sm), dysprosium (Dy), or terbium (Tb). In certain embodiments the oxide, in addition to the ytterbia and/or europia, further comprises lanthanum (La), praseodymium (Pr), or neodymium (Nd).

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials, methods for making these articles and materials, and methods for protecting articles using coatings made from these materials. One particular embodiment is an article that comprises a coating having a surface connected porosity content of up to about 5 percent by volume. The coating comprises a material that comprises a primary oxide and a secondary oxide, wherein (i) the primary oxide comprises a cerium cation, and (ii) the secondary oxide comprises a cation selected from the group consisting of the praseodymium and neodymium.

Abstract: A coating composition includes a cermet material having metal carbide phase particles with an average size of less than 5 microns. The coating has an average surface roughness of less than approximately 5 microns. A system for applying a coating to a substrate includes a spray gun configured for use with a high velocity oxygen or high velocity air fuel system. The system further includes a cermet material supplied to the spray gun, wherein the cermet material includes at least approximately 34 percent by weight of a metal carbide phase having an average particle size of less than or equal to approximately 5 microns. The metal carbide phase is dispersed in a liquid selected from the group consisting of water, alcohol, an organic combustible liquid, or an organic incombustible liquid.

Abstract: Different types of apparatus for fabricating a deposit, method of deposition and an article are presented. The apparatus include a thermal spray gun comprising a combustion chamber, combustion zone, an air injection port, a fuel injection port, a nozzle and a liquid injection port. The combustion zone exists between the inlet side and outlet side of the combustion chamber. The method includes, among other things, providing a fuel and an oxidizer inside the combustion zone, initiating combustion inside the combustion zone, and directing products of the combustion toward the outlet side to create a combustion product stream. The method also includes introducing a feedstock mixture comprising a feedstock material and a liquid into the combustion product stream to create an entrained feedstock stream, and expelling the entrained feedstock stream from the spray gun through a nozzle to form a deposit on a surface of the article.

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials. The oxide materials described herein as a class typically contain one or more of ytterbia (Yb2O3) and europia (Eu2O3). The oxides may further contain other additives, such as oxides of gadolinium (Gd), samarium (Sm), dysprosium (Dy), or terbium (Tb). In certain embodiments the oxide, in addition to the ytterbia and/or europia, further comprises lanthanum (La), praseodymium (Pr), or neodymium (Nd).

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials, methods for making these articles and materials, and methods for protecting articles using coatings made from these materials. One embodiment is a material comprising a primary oxide and a secondary oxide. The primary oxide comprises cerium or hafnium. The secondary oxide comprises (i) praseodymium or ytterbium, and (ii) another cation selected from the group consisting of the rare earth elements, yttrium, and scandium.

Abstract: A membrane structure is provided. The membrane structure includes a polymer layer having a plurality of pores; and a ceramic layer disposed on the polymer layer. The ceramic layer has a plurality of substantially unconnected pores. Each of the substantially unconnected pores is in fluid communication with at least one of the pores of the polymer layer. A method of manufacturing a membrane structure is provided. The method includes the steps of providing a polymer layer having a plurality of pores; and disposing a ceramic layer on the polymer layer. Disposing a ceramic layer includes depositing a metal layer on the polymer layer; and anodizing the metal layer to convert the metal layer into a porous layer. At least one of the depositing step and the anodizing step is performed as a continuous process. Alternatively, at least one of the depositing and the anodizing step is performed as a batch process.

Abstract: Ceramic materials with relatively high resistance to wetting by various liquids, such as water, are presented, along with articles made with these materials, methods for making these articles and materials, and methods for protecting articles using coatings made from these materials. One embodiment is an article comprising a material that is transparent to electromagnetic radiation of at least one type selected from the group consisting of ultraviolet radiation, visible light, and infrared radiation. The material comprises a primary oxide and a secondary oxide. The primary oxide comprises cerium or hafnium. The secondary oxide comprises (i) praseodymium or ytterbium, and (ii) another cation selected from the group consisting of the rare earth elements, yttrium, and scandium.