Abstract: A method for fabricating thermal barrier coatings. The thermal barrier coatings are produced with a fine grain size by reverse co-precipitation of fine powders. The powders are then sprayed by a solution plasma spray that partially melts the fine powders while producing a fine grain size with dense vertical cracking. The coatings comprise at least one of 45%-65% Yb2O3 the balance Zr, Yb/Y/Hf/Ta the balance Zr and 2.3-7.8% La, 1.4-5.1% Y and the balance Zr and are characterized by a thermal conductivity that is about 25-50% lower than that of thermal barrier coatings comprising YSZ. The thermal barrier coatings also are characterized by at least one of excellent erosion resistance, fracture toughness and abrasion resistance.

Abstract: A process of forming a calcium-magnesium-aluminosilicate (CMAS) penetration resistant coating, and a CMAS penetration resistant coating are disclosed. The process includes providing a thermal barrier coating having a dopant, and exposing the thermal barrier coating to calcium-magnesium-aluminosilicate and gas turbine operating conditions. The exposing forming a calcium-magnesium-aluminosilicate penetration resistant layer. The coating includes a thermal barrier coating composition comprising a dopant selected from the group consisting of rare earth elements, non-rare earth element solutes, and combinations thereof. Additional or alternatively, the coating includes a thermal barrier coating and an impermeable barrier layer or a washable sacrificial layer positioned on an outer surface of the thermal barrier coating.

Abstract: Disclosed herein is an erosion and corrosion resistant coating comprising a metallic binder, a plurality of hard particles, and a plurality of sacrificial particles. Also disclosed is a method of improving erosion and corrosion resistance of a metal component comprising disposing on a surface of the metal component the foregoing erosion and corrosion resistant coating comprising, and a metal component comprising a metal component surface and the foregoing erosion and corrosion resistant coating comprising a first surface and a second surface opposite the first surface, wherein the first surface is disposed on the metal component surface.

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.

Abstract: A seal system, for an apparatus that includes a rotatable portion with airfoils coupled thereto and a stationary portion with an inner surface, includes an abradable portion including at least one abradable layer of an abradable material formed over the inner surface. The seal system also includes an abrading portion disposed over at least a portion of a substrate of the airfoil. The abrading portion includes at least one abrading layer formed on at least a portion of the substrate and a plurality of abrasive particles embedded within the abrading layer. The plurality of abrasive particles includes at least one of substantially all of one of tantalum carbide (TaC), aluminum oxide (Al2O3), and ziconia (ZrO2), cubic boron nitride (cBN) and Al2O3 in predetermined ratios, cBN, Al2O3 and ZrO2 in predetermined ratios, Al2O3 and ZrO2 fused together in predetermined ratios, and TaC and Al2O3 in predetermined ratios.

Abstract: A method for use in determining the thickness of a layer of interest in a multi-layer structure. A first electrode is positioned in contact with a first surface of the multi-layer structure, and a second electrode is positioned in contact with a second surface of the multi-layer structure. The second surface is substantially opposite the first surface. The first electrode is pressed against the multi-layer structure at a predetermined sampling pressure, and the structure is optionally adjusted to a predetermined sampling temperature. The electrical impedance between the first electrode and the second electrode is measured.

Abstract: A compressor blade for use in a compressor section of a gas turbine engine, comprising: a martensitic stainless steel compressor blade and an abrasive coating having an anodic component. The compressor blade has a blade portion, a dovetail portion and a platform portion intermediate the blade portion and the dovetail portion, the blade portion terminating in a tip opposite the dovetail portion. A cobalt-based coating overlies at least the blade portion of the compressor blade. The cobalt-based coating comprises a cobalt based material that includes precipitates of tungsten carbide that provide erosion resistance and particles of a sacrificial metal-based material distributed through the cobalt-based coating that provide galvanic corrosion resistance to the system.

Abstract: Disclosed is a coating, a turbine component, and a process of fabricating a turbine component. The coating includes a ceramic phase formed by ceramic particles and a ductile matrix having a ductility greater than the ceramic phase. The ceramic phase includes substantially the same microstructure as the ceramic particles. The turbine component includes a surface having the coating. The process includes applying the coating to the surface of the turbine component.

Abstract: A titanium aluminide application process and article with a titanium aluminide surface are disclosed. The process includes cold spraying titanium aluminide onto an article within a treatment region to form a titanium aluminide surface. The titanium aluminide surface includes a refined gamma/alpha2 structure and/or the titanium aluminide is cold sprayed from a solid feedstock of a pre-alloyed powder.

Abstract: An enclosure system is provided having a shroud configured to cover at least a portion of a shaft. The shroud includes an input port and an output port. The input port is configured to accept at least one of a coating tool and an abrasive supplying tool. The output port is connected to a vacuum system.

Abstract: A titanium aluminide application process and article with a titanium aluminide surface are disclosed. The process includes cold spraying titanium aluminide onto an article within a treatment region to form a titanium aluminide surface. The titanium aluminide surface includes a refined gamma/alpha2 structure and/or the titanium aluminide is cold sprayed from a solid feedstock of a pre-alloyed powder.

Abstract: A process of applying a porous metallic structure and a cold-sprayed article are disclosed. The process includes cold spraying a solid feedstock and a low-melt material onto an article and removing at least a portion of the low-melt materials or applying a porous metallic structure includes cold spraying onto an article with two converging-diverging nozzles. The cold-sprayed article includes a porous metallic structure having a portion formed from cold spraying a solid feedstock. The portion includes the phases and microstructure of the solid feedstock.

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 self-lubricating brush seal assembly, for a power generation system and method of reducing air leakage in a power generation system including a plurality of self-lubricating members is provided. The plurality of self-lubricating members include a plurality of self-lubricating bristles, a plurality of cores sheathed in a self-lubricating braid, a plurality of cores having an outer diameter coated with self-lubricating material and a solid lubricating pack. The lubricating material is selected from graphite, hexagonal-boron nitrite (hBN), molybdenum disulfide (MoS2), tungsten disulfide (WS2), titanium nitride (TiN), titanium aluminum nitride (TiAlN), titanium carbonitride (TiCN), and combinations thereof.

Abstract: A vanadium resistant coating system resistant to high temperature vanadium attack. The system comprises a high temperature superalloy substrate. A bond coat overlies the superalloy substrate. The bond coat may be applied in multiple layers. A ceramic coating overlies the bond coat. The ceramic coating further comprises a zirconium oxide stabilized by at least one cation selected from the group consisting of Yb3+, Lu3+, Sc3+ and Ce4+, in the amounts of about 5-10 weight percent. An overcoat may overlie the ceramic coating. The overcoat may be a sacrificial layer of YSZ infiltrated with cations having an atomic radius larger than Y3+. Alternatively, the overcoat may comprise zirconium oxide stabilized by Ce4+.

Abstract: A method of coating a substrate with cryo-milled, nano-grained particles includes forming a face-centered-cubic gamma matrix comprising nickel, cobalt, chromium, tungsten and molybdenum, adding a dispersion strengthening material to the gamma matrix to form a first mixture, cryo-milling the first mixture to form a second mixture to form a nano-grained structure, and cold spraying the second mixture onto a substrate to form a coating having a nano-grained structure.

Abstract: A method for use in determining the thickness of a layer of interest in a multi-layer structure. A first electrode is positioned in contact with a first surface of the multi-layer structure, and a second electrode is positioned in contact with a second surface of the multi-layer structure. The second surface is substantially opposite the first surface. The first electrode is pressed against the multi-layer structure at a predetermined sampling pressure, and the structure is optionally adjusted to a predetermined sampling temperature. The electrical impedance between the first electrode and the second electrode is measured.

Abstract: A vanadium resistant coating system resistant to high temperature vanadium attack. The system comprises a high temperature superalloy substrate. A bond coat overlies the superalloy substrate. The bond coat may be applied in multiple layers. A ceramic coating overlies the bond coat. The ceramic coating further comprises a zirconium oxide stabilized by at least one cation selected from the group consisting of Yb3+, Lu3+, Sc3+ and Ce4+, in the amounts of about 5-10 weight percent. An overcoat may overlie the ceramic coating. The overcoat may be a sacrificial layer of YSZ infiltrated with cations having an atomic radius larger than Y3+. Alternatively, the overcoat may comprise zirconium oxide stabilized by Ce4+.

Abstract: A composition for a wear-resistant and low-friction coating is presented. The coating composition includes a hard ceramic phase, a metallic binder phase and a lubricant phase. The lubricant phase includes a multi-component oxide. An article having a wear-resistant and low-friction coating and a method of making such a coating are also described.

Abstract: A bandwidth divider and method for allocating bandwidth between a plurality of packet processors. The bandwidth divider includes a plurality of counters for measuring the bandwidth of data packets transferred from the bandwidth divider to a respective packet processor; and a controller for analyzing the plurality of counters and transferring a data packet to a selected packet processor based on the contents of the counters. The method monitors the bandwidth consumed by the packet processors; determines, based on the bandwidth consumed by the packet processors, which packet processor has consumed the least amount of bandwidth; and allocates a next data packet to the packet processor which has consumed the least amount of bandwidth.