Abstract: Methods are provided for forming a thermal barrier coating having a non-linear compositional gradient and/or a non-linear porosity gradient, along with coated components formed therefrom. The method includes spraying a deposition mixture of a first composition and a second composition via a solution precursor plasma spray apparatus onto a surface of a substrate; while spraying the deposition mixture, adjusting at least one deposition parameter such that the thermal barrier coating is formed with the non-linear gradient.

Abstract: Methods for repairing a thermal barrier coating deposited on a component with localized spallation of the thermal barrier coating includes depositing a primer slurry on a thermally grown oxide of the component exposed by the localized spallation, depositing a ceramic slurry on the primer slurry, and heating the primer slurry and the ceramic slurry. The primer slurry includes a primer that includes at least one of a metal and a metal oxide. The ceramic slurry includes a ceramic material, a ceramic slurry binder material, and a ceramic slurry fluid carrier. Heating the primer slurry and the ceramic slurry forms a first chemical bond between the primer and the thermally grown oxide and a second chemical bond between the primer and the ceramic material.

Abstract: Coated components, along with methods of their formation, are provided. The coated component may include a substrate having a surface and a thermal barrier coating on the surface of the substrate. The thermal barrier coating includes a plurality of elongated surface-connected voids therein, and wherein the thermal barrier coating comprises a plurality of nonspherical particles within a thermal barrier material.

Abstract: A sprayable thermal barrier coating powder mixture for a gas turbine engine includes: a dry composition having a low surface area ceramic powder having a median particle size distribution greater than 5 microns and less than 50 microns, and a high surface area ceramic powder having a median particle size distribution smaller than 5 microns, wherein the low surface area ceramic powder makes up at least 50% by weight of the dry composition of the sprayable thermal barrier coating powder mixture.

Abstract: A corrosion resistant coating including a matrix, corrosion resistant particles dispersed throughout the matrix, and a glass-forming additive is disclosed. The glass-forming additive and one or more materials in the matrix form a glassy-phase when cured. Coated gas turbine engine components and methods for coating components are also disclosed.

Abstract: A coated component of a gas turbine engine includes a substrate defining a surface, a thermal barrier coating deposited on the surface of the substrate, a region of the component where the thermal barrier coating has spalled from the substrate, a layer of environmental contaminant compositions formed on one or more of the thermal barrier coating or the region of the component where the thermal barrier coating has spalled from the substrate in response to an initial exposure of the component to high operating temperatures of the gas turbine engine, and a thermal barrier coating (TBC) restoration coating deposited at least on the region of the component where there thermal barrier coating has spalled from the substrate.

Abstract: Methods for forming a sintered patch on a silicon-based substrate are disclosed. The methods include applying a patch slurry on the silicon-based substrate, drying the patch slurry on the silicon-based substrate to form a dried patch material, and sintering the dried patch material in an oxidizing atmosphere to form a sintered patch on the silicon-based substrate. The patch slurry includes a patch material containing silicates in a fluid carrier.

Abstract: A sprayable thermal barrier coating powder mixture for a gas turbine engine includes: a dry composition having a low surface area ceramic powder having a median particle size distribution greater than 5 microns and less than 50 microns, and a high surface area ceramic powder having a median particle size distribution smaller than 5 microns, wherein the low surface area ceramic powder makes up at least 50% by weight of the dry composition of the sprayable thermal barrier coating powder mixture.

Abstract: A coated component of a gas turbine engine includes a substrate defining a surface, a thermal barrier coating deposited on the surface of the substrate, a region of the component where the thermal barrier coating has spalled from the substrate, a layer of environmental contaminant compositions formed on one or more of the thermal barrier coating or the region of the component where the thermal barrier coating has spalled from the substrate in response to an initial exposure of the component to high operating temperatures of the gas turbine engine, and a thermal barrier coating (TBC) restoration coating deposited at least on the region of the component where there thermal barrier coating has spalled from the substrate.

Abstract: A silicone bond coat composition having a viscosity of less than 1,600 centistokes is applied to substantially all external surfaces of the article and then cured. A liquid silicone elastomer outer coat composition comprising a high viscosity first liquid silicone elastomer formulation and a low viscosity second liquid silicone elastomer formulation is then applied and cured to provide a protected article having a complex shape. Optimal coatings result from a careful balancing of component viscosities. In an embodiment, the first formulation has a viscosity greater than 300,000 centistokes, and the second formulation has a viscosity less than 6,000 centistokes, and the liquid silicone elastomer outer coat composition comprises from about 60 to about 40 percent by weight of the first formulation and from about 40 to about 60 percent by weight of the second liquid silicone elastomer formulation.

Abstract: A magneto-caloric assembly can include a first region including a first magneto-caloric material, a second region disposed on the first region and including a second magneto-caloric material and a first matrix material, and a third region disposed on the second region and including a thermally conductive material.

Abstract: A silicone bond coat composition having a viscosity of less than 1,600 centistokes is applied to substantially all external surfaces of the article and then cured. A liquid silicone elastomer outer coat composition comprising a high viscosity first liquid silicone elastomer formulation and a low viscosity second liquid silicone elastomer formulation is then applied and cured to provide a protected article having a complex shape. Optimal coatings result from a careful balancing of component viscosities. In an embodiment, the first formulation has a viscosity greater than 300,000 centistokes, and the second formulation has a viscosity less than 6,000 centistokes, and the liquid silicone elastomer outer coat composition comprises from about 60 to about 40 percent by weight of the first formulation and from about 40 to about 60 percent by weight of the second liquid silicone elastomer formulation.

Abstract: A magneto-caloric assembly is provided. The assembly includes a first region comprising a first magneto-caloric material, a second region disposed on the first region and comprising a second magneto-caloric material and a first matrix material, and a third region disposed on the second region and comprising a thermally conductive material.

Abstract: A discharge lamp including an arc envelope defining a chamber and a first opening. A plug is positioned in the first opening through a first seal. The lamp further includes a dosing tube extending away from the chamber, and having a passageway extending into the chamber through a second opening in the arc envelope. The dosing tube is coupled to the arc envelope via a second seal. The first seal, the second seal, or both seals include a braze material having an active metal element in an amount ranging from about 0.1 weight percent to about 10 weight percent, based on the total weight of the braze material.

Abstract: The present disclosure generally relates to methods of using active braze techniques in high temperature rechargeable batteries. In some specific embodiments, the present disclosure relates to a method of sealing a portion of an insulated alpha alumina or spinel collar and a metal ring of a sodium metal halide battery.

Abstract: A sealing glass composition includes from about 10 molar percent to about 30 molar percent barium oxide, from about 15 molar percent to about 30 molar percent aluminum oxide, from about 40 molar percent to about 60 molar percent boron oxide and from about 1 molar percent to about 20 molar percent yttrium oxide. Methods for preparing the sealing glass and a sodium battery cell are also provided.

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: An apparatus, such as a plasma generation system, is provided. The apparatus can include a chamber that may be formed, for example, substantially of insulating material. The chamber can be configured to establish therein a stable glow discharge plasma having a pressure of at least about atmospheric pressure while vibrating a sample so as to be milled by bodies contained by the chamber. For example, the chamber may vibrate and/or rotate, and the chamber can include at least one body that includes insulating material and is free within the chamber. Associated methods are also provided.

Abstract: A sealing glass for an energy storage device is provided. The sealing glass includes silicon dioxide, boron oxide, aluminum oxide, sodium oxide and zirconium oxide. Methods for preparing the sealing glass and the energy storage device incorporating the sealing glass are also provided.

Abstract: A sealing glass for an energy storage device is provided. The sealing glass includes silicon dioxide, boron oxide, aluminum oxide, sodium oxide and zirconium oxide. Methods for preparing the sealing glass and the energy storage device incorporating the sealing glass are also provided.