Abstract: Plasma nozzle includes a nozzle body arranged to engage with a thermal spray gun. The nozzle body includes an axial through bore having up-stream input orifice and a down-stream nozzle exit, at least one material injector positioned between the up-stream input orifice and the nozzle-exit, said at least one material injector being configured to introduce a feedstock material into a gas flow passing through the axial through bore and at least one gas injector configured to introduce a shroud gas flow into the axial through bore and being located at a position up-stream of said at least one material injector.

Abstract: A superalloy workpiece includes a superalloy substrate and an interface layer (IF-1) of essentially the same superalloy composition directly on a surface of the superalloy substrate. A transition layer (TL) of essentially the same superalloy and superalloy oxides or a different metal composition and different metal oxides is on the interface layer (IF-1). The oxygen content of the transition layer increases from the interface layer (IF-1) towards a barrier layer (IF-2) of super alloy oxides or of different metal oxides.

Abstract: A layered stack that can be used as an oxidation and chemical barrier with superalloy substrates, including Ni, Ni—Co, Co, and Ni-aluminide based substrates, and methods of preparing the layered stack. The layer system can be applied to a substrate in a single physical vapor deposition process with no interruption of vacuum conditions.

Abstract: The present disclosure relates to a layer stack and methods of preparing the same for use as an oxidation and chemical barrier with superalloy substrates, including Ni, Ni—Co, Co, and Ni-aluminide based substrates. The layer system can be applied to a substrate in a single physical vapor deposition process with no interruption of vacuum conditions.

Abstract: Plasma nozzle includes a nozzle body arranged to engage with a thermal spray gun. The nozzle body includes an axial through bore having up-stream input orifice and a down-stream nozzle exit, at least one material injector positioned between the up-stream input orifice and the nozzle-exit, said at least one material injector being configured to introduce a feedstock material into a gas flow passing through the axial through bore and at least one gas injector configured to introduce a shroud gas flow into the axial through bore and being located at a position up-stream of said at least one material injector.

Abstract: Superalloy workpiece including a superalloy substrate and an interface layer (IF-1) of essentially the same superalloy composition directly on a surface of the superalloy substrate, followed by a transition layer (TL) of essentially the same superalloy and supperalloy oxides or a different metal composition and different metal oxides whereby oxygen content of the transition layer is increasing from IF-1 towards a barrier layer (IF-2) of super alloy oxides or of different metal oxides.

Abstract: A method of forming an abradable coating includes forming a plasma; introducing a coating material, as a powder having particles in the range between 1 and 50 ?m, carried by a delivery gas into the plasma, having a sufficiently high specific enthalpy for at least partially melting some of the powder and vaporizing at least 5% by weight of the powder, to form a vapor phase cloud of vapor and particles; forming a plasma beam by maintaining a process pressure between 50 and 2000 Pa; defocussing the plasma beam by maintaining a process pressure between 50 and 2000 Pa; and forming from the vapor phase cloud an abradable coating, comprising columnar structures. Advantageously, the columnar structured abradable coating has an erosion resistance smaller than 30 s/mils, preferably in the range of 5 to 27 s/mils, more preferably in the range 10-25 s/mils, still more preferably in the range 15-20 s/mils.

Abstract: A plasma spray method for the manufacture of an ion conducting membrane, in particular of a hydrogen ion conducting membrane or of an oxygen ion conducting membrane. In the method, the membrane is deposited as a layer on a substrate in a process chamber, wherein a starting material is sprayed onto a surface of the substrate by means of a process gas in the form of a process beam. The starting material is injected into a plasma at a low process pressure which is at most 10000 Pa and is partially or completely melted there. In accordance with the invention, the substrate has pores which are connected amongst one another so that the substrate is gas permeable and a portion of an overall pore area of an overall area of the coating surface amounts to at least 30% or, in a particular embodiment, to at least 40%.

Abstract: To apply a thermal barrier coating (10), a plasma jet (5) is generated by a plasma torch in a work chamber (2) and is directed to the surface of a substrate (3) introduced into the work chamber, and a ceramic coating material is applied to the substrate surface by means of PS-PVD, wherein the coating material is injected into the plasma jet as a powder and is partly or completely vaporized there. On applying the thermal barrier coating, in a first workstep the feed rate of the injected powder is set so that a large part of the injected powder vaporizes, wherein the coating material condenses from the vapor phase on the substrate surface and forms mixed phases with the material of the substrate surface.

Abstract: A plasma spray method for the manufacture of an ion conductive membrane is provided which ion conductive membrane has an ion conductivity, in which method the membrane is deposited as a layer (11) onto a substrate (10) in a process chamber, wherein a starting material (P) is sprayed onto a surface of the substrate (10) in the form of a process beam (2) by means of a process gas (G), wherein the starting material is injected into a plasma at a low process pressure, which is at most 10,000 Pa, and is partially or completely molten there. Oxygen (O2; 22) is supplied to the process chamber (12) during the spraying at a flow rate which amounts to at least 1%, preferably at least 2%, of the overall flow rate of the process gas.

Abstract: A method for the coating of a substrate in which a starting material (P) is sprayed onto the substrate in the form of a process jet by means of plasma spraying, with the starting material (P) being injected into a plasma which defocuses the process jet and being melted partly or completely into a liquid phase there at a low process pressure which is at most 20,000 Pa, wherein a gas flow for the process jet is set such that the substrate is coated by deposition from the liquid phase in at least one region which is located in the geometric shadow with respect to the process jet.

Abstract: A method of modifying a boundary region (9) of a substrate (3) bounded by a surface (10), wherein an evacuated process chamber (2) is provided having a plasma source (4) for generating a directed plasma jet (5), and wherein furthermore a reactive component is supplied into the process chamber (2) with a flow of a predefined size, and wherein the substrate (3) is heated to a predefined reaction temperature, characterized in that the reactive component is diffusion-activated by the directed plasma jet (5) such that the reactive component diffuses into the boundary region (11) of the substrate (3) at a predefinable diffusion rate.

Abstract: A plasma spray method for the manufacture of an ion conducting membrane, in particular of a hydrogen ion conducting membrane or of an oxygen ion conducting membrane is suggested. In which method the membrane is deposited as a layer (11) on a substrate (10) in a process chamber, wherein a starting material (P) is sprayed onto a surface of the substrate (10) by means of a process gas (G) in the form of a process beam (2). The starting material is injected into a plasma at a low process pressure which is at most 10000 Pa and is partially or completely melted there. In accordance with the invention the substrate (10) has pores (30) which are connected amongst one another so that the substrate (10) is gas permeable and a portion of an overall pore area of an overall area of the coating surface (31, 131) amounts to at least 30%, in particular to at least 40%.

Abstract: To manufacture a thermal barrier coating structure on a substrate surface, a working chamber having a plasma torch is provided, a plasma jet is generated in that a plasma gas is conducted through the plasma torch and is heated therein by means of electric gas discharge, electromagnetic induction or microwaves, and the plasma jet is directed to the surface of a substrate introduced into the working chamber. To manufacture the thermal barrier coating, a voltage is additionally applied between the plasma torch and the substrate to generate an arc between the plasma torch and the substrate and the substrate surface is cleaned by means of the light arc, wherein the substrate remains in the working chamber after the arc cleaning and an oxide layer is generated on the cleaned substrate surface and a thermal barrier coating is applied by means of a plasma spray process.

Abstract: A plasma spray method for the manufacture of an ion conductive membrane is provided which ion conductive membrane has an ion conductivity, in which method the membrane is deposited as a layer (11) onto a substrate (10) in a process chamber, wherein a starting material (P) is sprayed onto a surface of the substrate (10) in the form of a process beam (2) by means of a process gas (G), wherein the starting material is injected into a plasma at a low process pressure, which is at most 10,000 Pa, and is partially or completely molten there. Oxygen (O2; 22) is supplied to the process chamber (12) during the spraying at a flow rate which amounts to at least 1%, preferably at least 2%, of the overall flow rate of the process gas.

Abstract: A method for the coating of a substrate in which a starting material (P) is sprayed onto the substrate in the form of a process jet by means of plasma spraying, with the starting material (P) being injected into a plasma which defocuses the process jet and being melted partly or completely into a liquid phase there at a low process pressure which is at most 20,000 Pa, wherein a gas flow for the process jet is set such that the substrate is coated by deposition from the liquid phase in at least one region which is located in the geometric shadow with respect to the process jet.

Abstract: A plasma coating plant for coating or treating the surface of a substrate having a work chamber which can be evacuated and into which the substrate can be placed, and having a plasma torch for generating a plasma jet by heating a process gas, wherein the plasma torch has a nozzle through which the plasma jet can exit the plasma torch and can extend along a longitudinal axis (A) into the work chamber, wherein a mechanical limiting apparatus is provided downstream of the nozzle in the work chamber, which mechanical limiting apparatus extends along the longitudinal axis (A) and protects the plasma jet against an unwanted lateral intrusion of particles. A corresponding method is also disclosed.

Abstract: A method is proposed of coating a surface of a body which has at least one throughgoing bore having an inlet and having an outlet, wherein the outlet is provided in the surface to be coated, in which method the coating takes place by means of thermal spraying, wherein, during the thermal spraying, the bore is flowed through by a fluid which flows out through the outlet of the bore and substantially prevents a constriction of the bore caused by the coating.