Abstract: The present invention provides methods and materials for use in applying a coating on a surface of a magnesium component. The method includes the steps of: accelerating a coating powder to a velocity of between about 500 to about 1200 meters/second, wherein the coating powder comprises a material selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, and composites; directing the coating powder through a convergent-divergent nozzle onto the surface of the magnesium component; and forming a coating on the surface of the magnesium component so as to substantially cover the surface of the magnesium component. The coating thickness may be between approximately 0.1 to approximately 1.0 mm.

Abstract: A method for joining a first component surface to a ceramic component surface includes cold gas-dynamic spraying a first metal powder onto the ceramic component surface to form a first metal coating. The first component surface is then bonded to the metal coating on the ceramic component surface. The bonding step may be a thermal process such as a brazing process. A mechanical bond may also be formed by an interference fitting such as press or shrink fitting.

Abstract: The present invention provides a chromium and active elements modified platinum aluminide coating that may be used on a surface of a gas turbine engine component such as a turbine blade. The coating may be used as a protective coating that impedes the progress of corrosion, oxidation, and sulfidation in superalloy materials that comprise the substrate of the turbine blade. Additionally, the coating may be used as a bond coat onto which a thermal barrier coating is deposited. The presence of active elements as well as chromium and platinum provides improved corrosion, oxidation, and sulfidation resistance. The coating is applied using an electron beam physical vapor deposition. The coating is applied alternatively using selected sequential diffusion processing steps involving chromium, platinum and aluminum.

Abstract: A method of forming a wear-resistant coating on a substrate surface includes the step of cold gas-dynamic spraying a material comprising a rhenium-based composition onto the substrate surface. A metal layer may be formed on the substrate surface prior to the cold gas-dynamic spraying step, and a heat treatment may be performed after the gold gas-dynamic spraying step.

Abstract: A method is provided for forming a graded coating on a surface of a substrate. The method comprises the step of cold gas-dynamic spraying powder mixtures on the substrate surface to form the graded coating thereon. The method does not distort the substrate and does not require the use of an apparatus that needs to be stopped and re-started each time the composition of the graded coating changes. Moreover, the method is generally inexpensive, efficient, and yields high quality graded coatings.

Abstract: A plurality of powders is admixed to form a substantially homogenous powder mixture comprising each of the alloy elements. At least one of the powders consists essentially of a substantially pure elemental metal. The substantially homogenous powder mixture is cold gas-dynamic sprayed on the substrate to form a coating of the alloy elements. The coating is then heated until the alloy elements inter-diffuse and form the alloy. In an exemplary embodiment, the substantially homogenous powder mixture includes stoichiometric amounts of each of the alloy elements, and each of the powders consists essentially of a substantially pure form of one of the alloy elements.

Abstract: A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.

Abstract: A method for coating a surface of a metal component comprises the steps of cold gas-dynamic spraying a powder material on the metal component surface to form a coating, the powder material being sufficiently heated to impact the metal component surface at between about 30% and about 70% of the powder material's melting temperature in kelvins. Another method for coating a surface of a metal component using a powder material comprises the steps of heating the metal component surface to between about 30% and about 70% of the substrate's melting temperature, and then of the powder material's melting temperature in kelvins, and cold gas-dynamic spraying the powder material on the metal component surface to form a coating.

Abstract: The present invention provides methods and materials for use in applying a coating on a surface of a magnesium component. The method includes the steps of: accelerating a coating powder to a velocity of between about 500 to about 1200 meters/second, wherein the coating powder comprises a material selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, and composites; directing the coating powder through a convergent-divergent nozzle onto the surface of the magnesium component; and forming a coating on the surface of the magnesium component so as to substantially cover the surface of the magnesium component. The coating thickness may be between approximately 0.1 to approximately 1.0 mm.

Abstract: The present invention provides a chromium and active elements modified platinum aluminide coating that may be used on a surface of a gas turbine engine component such as a turbine blade. The coating may be used as a protective coating that impedes the progress of corrosion, oxidation, and sulfidation in superalloy materials that comprise the substrate of the turbine blade. Additionally, the coating may be used as a bond coat onto which a thermal barrier coating is deposited. The presence of active elements as well as chromium and platinum provides improved corrosion, oxidation, and sulfidation resistance. The coating is applied using an electron beam physical vapor deposition. The coating is applied alternatively using selected sequential diffusion processing steps involving chromium, platinum and aluminum.

Abstract: A method for repairing a titanium alloy surface of a turbine component includes the step of cold gas-dynamic spraying a powder material comprising at least one titanium alloy directly on the titanium alloy surface. The method may further include the steps of hot isostatic pressing the cold gas-dynamic sprayed turbine component, and performing a separate heat treating step after the hot isostatic pressing. Thus, the cold gas-dynamic spray process and post-spray processing can be employed to effectively repair degraded areas on compressor turbine components.

Abstract: There is provided a method for applying a diffusion coating on a specific area of targeted industrial item such as a turbine blade. The method uses a covering material such as a tape or slurry to cover the area where it is desired that the diffusion occur, for example above the root area of a turbine blade. The tape material includes a metallic source such as chromium and a master alloy of active elements for diffusion. The covering material thus defines the localized patch that is to be coated. An activator if any, such as a halide activator, can be included in the tape or slurry. Alternatively, the activator can be included in the pack material. The method uses known pack cementation methods to complete the diffusive process. The method results in a diffusion coating over a specific area of the target item.