Abstract: A coated turbomachine component includes a ceramic component body having a principal surface. The component includes a high temperature coating. The high temperature coating includes a sintered coating body bonded directly to and intimately contacting the principal surface of the ceramic component body. The sintered coating body has a minimum porosity adjacent the principal surface and a maximum porosity at a location further from the principal surface, as taken along an axis orthogonal to the principal surface.

Abstract: Embodiments of laminated stator cores suitable for usage in high temperature applications are provided, as are embodiments of methods for manufacturing high temperature laminated stator core. In one embodiment, the method includes obtaining a plurality of coated laminates each comprising a laminate over which a coating precursor layer is formed. The coating precursor layer contain inorganic dielectric particles having a softening point. The plurality of coated laminates are arranged in a laminate stack, which is then fired at temperatures equal to or greater than the softening point of the inorganic dielectric particles. During firing, a compressive force is applied to the laminate stack sufficient to consolidate the inorganic dielectric particles into a plurality of coherent interlaminate dielectric layers electrically insulating and bonding together the plurality of coated laminates as the high temperature laminated stator core.

Abstract: Methods for forming sintered-bonded high temperature coatings over ceramic turbomachine components are provided, as are ceramic turbomachine components having such high temperature coatings formed thereover. In one embodiment, the method includes the step or process of removing a surface oxide layer from the ceramic component body of a turbomachine component to expose a treated surface of the ceramic component body. A first layer of coating precursor material, which has a solids content composed predominately of at least one rare earth silicate by weight percentage, is applied to the treated surface. The first layer of the coating precursor material is then heat treated to sinter the solids content and form a first sintered coating layer bonded to the treated surface. The steps of applying and sintering the coating precursor may be repeated, as desired, to build a sintered coating body to a desired thickness over the ceramic component body.

Abstract: Methods for forming sintered-bonded high temperature coatings over ceramic turbomachine components are provided, as are ceramic turbomachine components having such high temperature coatings formed thereover. In one embodiment, the method includes the step or process of removing a surface oxide layer from the ceramic component body of a turbomachine component to expose a treated surface of the ceramic component body. A first layer of coating precursor material, which has a solids content composed predominately of at least one rare earth silicate by weight percentage, is applied to the treated surface. The first layer of the coating precursor material is then heat treated to sinter the solids content and form a first sintered coating layer bonded to the treated surface. The steps of applying and sintering the coating precursor may be repeated, as desired, to build a sintered coating body to a desired thickness over the ceramic component body.

Abstract: Methods are disclosed for fabricating heat exchangers and Heat Exchanger (HX) tubes, as are heat exchangers fabricated in accordance with such methods. In embodiments, the method includes fabricating an HX tube by at least partially forming the elongated tube body utilizing a cold spray process during which a metallic feedstock powder is deposited over a removable mandrel. The HX tube is separated from the removable mandrel at some juncture following cold spray deposition of the tube body.

Abstract: Methods are disclosed for fabricating heat exchangers and Heat Exchanger (HX) tubes, as are heat exchangers fabricated in accordance with such methods. In embodiments, the method includes the steps or processes of obtaining a Non-Equilibrium Alloy (NEA) feedstock powder comprised of an alloy matrix throughout which at least one minority constituent is dispersed. The first minority constituent precipitates from the alloy matrix when the NEA feedstock powder is exposed to temperatures exceeding a critical temperature threshold (TCRITICAL) for a predetermined time period. A cold spray process is carried-out to at least partially form the HX tubes from the NEA feedstock powder; and the HX tubes are subsequently installed in the heat exchanger. The HX tubes are exposed to a maximum temperature (TSPRAY_MAX) during the cold spray process, which is maintained below TCRITICAL to substantially preserve the non-equilibrium state of the NEA feedstock powder through cold spray deposition.

Abstract: Embodiments of a method for producing powder mixtures having uniform dispersion of ceramic particles within larger superalloy particles are provided, as are embodiments of superalloy powder mixtures. In one embodiment, the method includes producing an initial powder mixture comprising ceramic particles mixed with superalloy mother particles having an average diameter larger than the average diameter of the ceramic particles. The initial powder mixture is formed into a consumable solid body. At least a portion of the consumable solid body is gradually melted, while the consumable solid body is rotated at a rate of speed sufficient to cast-off a uniformly dispersed powder mixture in which the ceramic particles are embedded within the superalloy mother particles.

Abstract: Methods for fabricating wires insulated by low porosity glass coatings are provided, as are high temperature electromagnetic (EM) devices containing such wires. In embodiments, a method for fabricating a high temperature EM device includes applying a glass coating precursor material onto a wire. The glass coating precursor material contains a first plurality of glass particles having an initial softening point. after application onto the wire, the glass coating precursor material is heat treated under process conditions producing a crystallized intermediary glass coating having a modified softening point exceeding the initial softening point. The crystallized intermediary glass coating is then infiltrated with a filler glass precursor material containing a second plurality of glass particles.

Abstract: This disclosure provides a method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate to form an article. The method includes the steps of etching the surface of the ceramic substrate to texture the surface, disposing an environmental barrier coating on the etched surface of the ceramic substrate wherein the environmental barrier coating includes a rare earth silicate, and pressure sintering the environmental barrier coating on the etched surface of the ceramic substrate in an inert or nitrogen atmosphere at a pressure of greater than atmospheric pressure such that at least a portion of the environmental barrier coating is disposed in the texture of the surface of the ceramic substrate thereby forming the article.

Abstract: Coatings containing nickel-tungsten (NiW) plating layers are provided, as are methods for forming coatings and NiW plating layers over metallic components. In embodiments, the method includes preparing a plating bath containing a tungsten (W) ion source; inserting at least one consumable nickel (Ni) electrode and at least a portion of the metallic component into the plating bath; and, afterwards, electrodepositing a NiW plating layer over the component surface by energizing the at least one consumable Ni electrode as an anode and the metallic component as a cathode to attract Ni ions and W ions to the component surface. An amount of anode corrosion accelerant in the plating bath is controlled to balance Ni dissolution at the anode to Ni deposition at cathode, as considered in conjunction with any additional Ni ion sources within the plating bath, to achieve a desired composition of the electrodeposited NiW layer.

Abstract: Ionic liquid bath plating methods for depositing aluminum-containing layers utilizing shaped consumable aluminum anodes are provided, as are turbomachine components having three dimensionally-tailored, aluminum-containing coatings produced from such aluminum-containing layers. In one embodiment, the ionic liquid bath plating method includes the step or process of obtaining a consumable aluminum anode including a workpiece-facing anode surface substantially conforming with the geometry of the non-planar workpiece surface. The workpiece-facing anode surface and the non-planar workpiece surface are positioned in an adjacent, non-contacting relationship, while the workpiece and the consumable aluminum anode are submerged in an ionic liquid aluminum plating bath. An electrical potential is then applied across the consumable aluminum anode and the workpiece to deposit an aluminum-containing layer onto the non-planar workpiece surface.

Abstract: Methods for depositing wear resistant NiW plating systems on metallic components are provided. In various embodiments, the method includes the step or process of preparing a NiW plating bath containing a particle suspension. The NiW plating bath is prepared by introducing wear resistant particles into the NiW plating path and adding at least one charged surfactant. The first type of wear resistant particles and the first charged surfactant may be contacted when introduced into the NiW plating bath or prior to introduction into the NiW plating bath. The at least one charged surfactant binds with the wear resistant particles to form a particle-surfactant complex. The wear resistant NiW plating system is then electrodeposited onto a surface of a component at least partially submerged in the NiW plating bath. The resulting wear resistant NiW plating system comprised of a NiW matrix in which the wear resistant particles are embedded.

Abstract: Methods for producing a coated component are provided, as are coated components having wear resistant coatings. In embodiments, the method includes the step or process of fabricating, purchasing, or otherwise obtaining a component having a component surface. An XP alloy body is formed over the component surface to yield a coated component, wherein P is phosphorus and X is cobalt, nickel, or a combination thereof. After formation of the XP alloy body, the XP alloy body is machined; and, following machining, the coated component is heat treated to precipitate harden the XP alloy body. In certain embodiments, heat treatment may be conducted to concurrently anneal the underlying component in conjunction with precipitation hardening of the XP alloy body. In other instances, the method further includes the step of forming a barrier layer over the component surface prior to deposition of the XP alloy body.

Abstract: Embodiments of a method for producing powder mixtures having uniform dispersion of ceramic particles within larger superalloy particles are provided, as are embodiments of superalloy powder mixtures. In one embodiment, the method includes producing an initial powder mixture comprising ceramic particles mixed with superalloy mother particles having an average diameter larger than the average diameter of the ceramic particles. The initial powder mixture is formed into a consumable solid body. At least a portion of the consumable solid body is gradually melted, while the consumable solid body is rotated at a rate of speed sufficient to cast-off a uniformly dispersed powder mixture in which the ceramic particles are embedded within the superalloy mother particles.

Abstract: Ionic liquid bath plating methods for depositing aluminum-containing layers utilizing shaped consumable aluminum anodes are provided, as are turbomachine components having three dimensionally-tailored, aluminum-containing coatings produced from such aluminum-containing layers. In one embodiment, the ionic liquid bath plating method includes the step or process of obtaining a consumable aluminum anode including a workpiece-facing anode surface substantially conforming with the geometry of the non-planar workpiece surface. The workpiece-facing anode surface and the non-planar workpiece surface are positioned in an adjacent, non-contacting relationship, while the workpiece and the consumable aluminum anode are submerged in an ionic liquid aluminum plating bath. An electrical potential is then applied across the consumable aluminum anode and the workpiece to deposit an aluminum-containing layer onto the non-planar workpiece surface.

Abstract: Methods are disclosed for fabricating heat exchangers and Heat Exchanger (HX) tubes, as are heat exchangers fabricated in accordance with such methods. In embodiments, the method includes the steps or processes of obtaining a Non-Equilibrium Alloy (NEA) feedstock powder comprised of an alloy matrix throughout which at least one minority constituent is dispersed. The first minority constituent precipitates from the alloy matrix when the NEA feedstock powder is exposed to temperatures exceeding a critical temperature threshold (TCRITICAL) for a predetermined time period. A cold spray process is carried-out to at least partially form the HX tubes from the NEA feedstock powder; and the HX tubes are subsequently installed in the heat exchanger. The HX tubes are exposed to a maximum temperature (TSPRAY_MAX) during the cold spray process, which is maintained below TCRITICAL to substantially preserve the non-equilibrium state of the NEA feedstock powder through cold spray deposition.

Abstract: Ionic liquid bath plating systems, methods, and plating anodes are provided for depositing metallic layers over turbomachine components and other workpieces. In an embodiment, the method includes placing workpieces in a plurality of cell vessels such that the workpieces are at least partially submerged in plating solution baths, which are retained within the cell vessels when the plating system is filled with a selected non-aqueous plating solution. After plating anodes are positioned adjacent the workpieces in the plating solution baths, the plurality of cell vessels are enclosed with lids such that the plurality of cell vessels contain vessel headspaces above the plating solution baths. A first purge gas is then injected into the plurality of cell vessels to purge the vessel headspaces. The workpieces and the plating anodes are then energized to deposit metallic layers on selected surfaces of the workpieces utilizing an ionic liquid bath plating process.

Abstract: Methods for producing Non-Equilibrium Alloy (NEA) feedstock powders are disclosed, as are methods for fabricating articles from such NEA feedstock powders utilizing Additive Manufacturing (AM) cold spray processes. In various embodiments, the method includes the step or process obtaining an NEA feedstock powder, which is composed of an alloy matrix throughout which a first minority constituent is dispersed. The first minority constituent precipitates from the alloy matrix when the NEA feedstock powder is exposed to temperatures exceeding a critical temperature threshold (TCRITICAL) for a predetermined time period. An AM cold spray process is carried-out to produce a near-net article from the NEA feedstock powder, which is exposed to a maximum temperature (TSPRAY_MAX) during the cold spray process. The near-net article is then further processed to yield a finished article.

Abstract: Ionic liquid bath plating systems, methods, and plating anodes are provided for depositing metallic layers over turbomachine components and other workpieces. In an embodiment, the method includes placing workpieces in a plurality of cell vessels such that the workpieces are at least partially submerged in plating solution baths, which are retained within the cell vessels when the plating system is filled with a selected non-aqueous plating solution. After plating anodes are positioned adjacent the workpieces in the plating solution baths, the plurality of cell vessels are enclosed with lids such that the plurality of cell vessels contain vessel headspaces above the plating solution baths. A first purge gas is then injected into the plurality of cell vessels to purge the vessel headspaces. The workpieces and the plating anodes are then energized to deposit metallic layers on selected surfaces of the workpieces utilizing an ionic liquid bath plating process.

Abstract: Embodiments of laminated stator cores suitable for usage in high temperature applications are provided, as are embodiments of methods for manufacturing high temperature laminated stator core. In one embodiment, the method includes obtaining a plurality of coated laminates each comprising a laminate over which a coating precursor layer is formed. The coating precursor layer contain inorganic dielectric particles having a softening point. The plurality of coated laminates are arranged in a laminate stack, which is then fired at temperatures equal to or greater than the softening point of the inorganic dielectric particles. During firing, a compressive force is applied to the laminate stack sufficient to consolidate the inorganic dielectric particles into a plurality of coherent interlaminate dielectric layers electrically insulating and bonding together the plurality of coated laminates as the high temperature laminated stator core.