Abstract: An intermediate solid oxide fuel cell (SOFC) stage and methods for inspecting an assembled portion of an SOFC are presented. One method for inspecting an assembled portion of an SOFC includes applying a pneumatic constraint to a fluid, where the fluid is in communication with the assembled portion of the SOFC, determining a quality control parameter of the assembled portion of the SOFC in response to the pneumatic constraint, and ascertaining health of the assembled portion of the SOFC based on the quality control parameter. The assembled portion of the SOFC includes a metallic interconnect, where the metallic interconnect includes a flow field.

Abstract: An intermediate solid oxide fuel cell (SOFC) stage and methods for inspecting an assembled portion of an SOFC are presented. One method for inspecting an assembled portion of an SOFC includes applying a pneumatic constraint to a fluid, where the fluid is in communication with the assembled portion of the SOFC, determining a quality control parameter of the assembled portion of the SOFC in response to the pneumatic constraint, and ascertaining health of the assembled portion of the SOFC based on the quality control parameter. The assembled portion of the SOFC includes a metallic interconnect, where the metallic interconnect includes a flow field.

Abstract: Coating systems for components of a gas turbine engine, such as a compressor casing, are provided. The coating system can include a ceramic material disposed along the compressor casing on a surface to be adjacent to a rotating compressor blade. The coating system is harder than the compressor blade and can reduce the rub ratio between the casing and blade. The coating system can thereby increase the lifetime of the compressor casing and blades. Methods are also provided for applying the coating system onto a compressor casing.

Abstract: A rare earth silicate-based hermetic layer includes a thermal sprayed coating including a rare earth silicate having a hermetic microstructure. An environmental barrier coating includes a bond coat layer including silicon; and at least one rare earth silicate-based hermetic layer deposited on the bond coat layer by thermal spraying. The rare earth silicate-based hermetic layer includes a thermal sprayed coating including a rare earth silicate having a hermetic microstructure. An article for service in extreme environments may be provided with such an environmental barrier coating. A thermal spray feedstock for producing a rare earth silicate-based hermetic 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: An apparatus for enhancing the coalescence of a dispersed phase from a continuous phase in an emulsion is presented. The apparatus includes at least one inlet for receiving the emulsion, at least one outlet for discharging the emulsion after coalescing the dispersed phase, and at least one article disposed between the inlet and the outlet. The article includes a plurality of regions disposed on a surface in a predefined pattern, wherein a portion of the plurality of regions is substantially wetting with respect to the dispersed phase, and a portion of the plurality of regions is substantially non-wetting with respect to the dispersed phase, and wherein the pattern includes a plurality of inter-connected regions that are substantially non-wetting with respect to the dispersed phase. A related article is also presented.

Abstract: A rare earth silicate-based hermetic layer includes a thermal sprayed coating including a rare earth silicate having a hermetic microstructure. An environmental barrier coating includes a bond coat layer including silicon; and at least one rare earth silicate-based hermetic layer deposited on the bond coat layer by thermal spraying. The rare earth silicate-based hermetic layer includes a thermal sprayed coating including a rare earth silicate having a hermetic microstructure. An article for service in extreme environments may be provided with such an environmental barrier coating. A thermal spray feedstock for producing a rare earth silicate-based hermetic layer.

Abstract: An abradable seal having a metallic substrate and a multi-layered ceramic coating on the metallic substrate. The multi-layered ceramic coating includes a base layer deposited on the metallic substrate, an abradable layer overlaying the first layer, and an abrading layer overlaying the second layer. The abrading layer is formed of an abrading material. A turbine system and a method for forming an abradable seal are also disclosed.

Abstract: Methods of manufacturing turbine shrouds with an abradable coating that balance the apparently contradictory requirements of high flowpath solidity, low blade tip wear, and good durability in service may include forming an abradable coating on a surface of a coating system to form a substantially smooth flowpath surface. Forming the abradable coating includes forming a relatively porous, smooth abradable coating. The methods may also include machining the abradable so as to achieve a substantially smooth flowpath surface.

Abstract: Methods of manufacturing turbine shrouds with an abradable coating that balance the apparently contradictory requirements of high flowpath solidity, low blade tip wear, and good durability in service. The methods include obtaining a shroud substrate. The methods may include obtaining a coating system on the shroud substrate. The methods include forming an abradable coating on a surface of the coating system so as to form a substantially smooth flowpath surface. Forming the abradable coating includes forming a relatively dense scaffold and relatively porous filler regions in-between the relatively dense abradable scaffold. The methods may also include machining the abradable so as to achieve a substantially smooth flowpath surface comprising a relatively porous abradable phase surrounded by a relatively dense, high-durability corrale phase.

Abstract: Turbine shroud abradable coatings that balance the apparently contradictory requirements of high flowpath solidity, low blade tip wear, and good durability in service. The shrouds include a shroud substrate, a coating system, and an abradable coating. The coating system overlies at least a portion of an outer surface of the shroud substrate. The coating system includes a bond coat, a thermal barrier coating (TBC), and/or an environmental barrier coating (EBC). The abradable coating overlies at least a portion of the barrier coating. The abradable coating defines a substantially smooth continuous flowpath surface. The abradable coating includes a hybrid microstructure including a relatively dense, high-durability phase corralling relatively porous abradable phases. The second phases are relatively more abradable by the blades of a turbine than the second regions.

Abstract: A method for the formation of channels on a metallic substrate is described. The method includes the steps of applying at least one layer of a metallic coating material onto a surface of the substrate by a cold spray technique, so as to define boundary walls for the channels, and to build the boundary walls to a desired height. Additional coating material is then applied on one or more surfaces of the boundary walls by the cold spray technique, so as to modify the shape of the channels. The substrate can be any type of high-temperature component or hot gas path component. In some instances, the substrate is a gas turbine engine wall.

Abstract: An apparatus for enhancing the coalescence of a dispersed phase from a continuous phase in an emulsion is presented. The apparatus includes at least one inlet for receiving the emulsion, at least one outlet for discharging the emulsion after coalescing the dispersed phase, and at least one article disposed between the inlet and the outlet. The article includes a plurality of regions disposed on a surface in a predefined pattern, wherein a portion of the plurality of regions is substantially wetting with respect to the dispersed phase, and a portion of the plurality of regions is substantially non-wetting with respect to the dispersed phase, and wherein the pattern includes a plurality of inter-connected regions that are substantially non-wetting with respect to the dispersed phase. A related article is also presented.

Abstract: A method for manufacturing an article configured to enhance the coalescence of a dispersed phase from a continuous phase in an emulsion is presented. The method includes forming a pattern of a plurality of regions on a surface of the article, wherein a portion of the plurality of regions is substantially wetting with respect to the dispersed phase, and a portion of the plurality of regions is substantially non-wetting with respect to the dispersed phase. The pattern further includes a plurality of inter-connected regions that are substantially non-wetting with respect to the dispersed phase.

Abstract: An article includes a substrate with a coating having asperities such that an average spacing between the asperities is between about 0.01 and about 1.5 micron. An average surface roughness of the coating is up to about 2 microns, and an average porosity of the coating is in the range from about 35% to about 70%. A material to reduce surface energy is disposed on the coating. A method for making such an article and a method for decreasing fluid drag across such an article are also provided.

Abstract: A method of coating a surface is provided. The method comprises feeding a feedstock to a thermal spray torch, the feedstock comprising a liquid, disposing the feedstock on a substrate by thermal spray under conditions selected to produce a textured surface comprising a hierarchical structure, wherein the hierarchical structure comprises agglomerations of at least partially melted and solidified particles derived from the feedstock with individual at least partially melted and solidified particles derived from the feedstock disposed on a surface of the agglomerations; and applying a surface energy modification material over the textured surface. An article comprising a component having a coated surface is also provided.

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: Coatings and articles suitable for use in high temperature environments, for example, are presented. One embodiment is a coating that comprises a plurality of elongate material growth domains defined between domain boundaries. The domains have an intra-domain density of at least about 75% of theoretical density, have a substantially equiaxed grain morphology, and comprise a plurality of at least partially melted and solidified particles. Another embodiment is a coating that comprises a matrix comprising a substantially equiaxed grain morphology and a plurality of vertically oriented cracks disposed in the matrix. Further embodiments include articles comprising one or more of the coatings described above.

Abstract: Coatings and articles suitable for use in high temperature environments, for example, are presented. One embodiment is a coating that comprises a plurality of elongate material growth domains defined between domain boundaries. The domains have an intra-domain density of at least about 75% of theoretical density, have a substantially equiaxed grain morphology, and comprise a plurality of at least partially melted and solidified particles. Another embodiment is a coating that comprises a matrix comprising a substantially equiaxed grain morphology and a plurality of vertically oriented cracks disposed in the matrix. Further embodiments include articles comprising one or more of the coatings described above.

Abstract: A method of forming a coating comprises depositing a first coating layer on a surface of a substrate, wherein the coating comprises a ceramic or metal, a lubricant, and a fugitive material. At least a portion of the fugitive material is decomposed, transformed or volatized by heating the first coating layer with a localized heat source.