Abstract: A coating on a substrate is disclosed having layers including yttrium aluminum garnet (YAG) and yttrium aluminum monoclinic (YAM).

Abstract: A coating on a substrate is disclosed having layers including yttrium aluminum garnet (YAG) and yttrium aluminum monoclinic (YAM).

Abstract: A coating on a substrate is disclosed having layers including yttrium aluminum garnet (YAG) and yttrium aluminum perovskite (YAP).

Abstract: A method for manufacturing a coating includes dissolving at least one salt in a mixture of water and ethanol to form a precursor solution, adding an additive to the precursor solution to form a fuel solution, and injecting the fuel solution into a plasma flame. The additive includes at least one of urea or ammonium acetate. The additive functions as a fuel to increase a temperature of the plasma flame. The method further includes manufacturing the coating on a substrate. The coating includes a garnet structure including a predetermined amount of yttrium-aluminum, one or more first cracks extending completely through a thickness of the coating, and a porosity greater than ten volume percent.

Abstract: A multi-layer coating that allows arrest of contaminant infiltration includes at least one layer that is not very reactive to an infiltrating reactive species, and at least one highly reactive ceramic layer (HRC layer) containing materials that react to slow or arrest contaminant infiltration.

Abstract: Embodiments of a microstructure that allows arrest of contaminant infiltration includes an inter layer and at least one highly reactive ceramic layer. The inter layer is not reactive to an infiltrating reactive species. The HRC layer includes materials that react with a reactive contaminant species to slow or arrest infiltration of such contaminant species.

Abstract: A solution precursor plasma spray process (SPPS) produces compositionally graded and porosity graded coatings with no discrete interfaces and with reduced coating stress and improved coating durability. The disclosed SPPS process may fabricate superior thick monolithic thermal barrier coatings with engineered microstructural defects (cracks, pores) and thin, dense coatings for a variety of engineering applications. The disclosed coatings may possess a continuous variation of one or more physical properties selected from density, thermal conductivity, emissivity, thermal expansion coefficient, abrasion resistance, erosion resistance, hardness, fracture toughness, gas penetration resistance, liquid penetration resistance, elastic modulus, and strain tolerance.

Abstract: A coating on a substrate is disclosed having layers including yttrium aluminum garnet (YAG) and yttrium aluminum perovskite (YAP).

Abstract: Embodiments of a microstructure that allows arrest of contaminant infiltration includes an inter layer and at least one highly reactive ceramic layer. The inter layer is not reactive to an infiltrating reactive species. The HRC layer includes materials that react with a reactive contaminant species to slow or arrest infiltration of such contaminant species.

Abstract: A thermal barrier coating that includes a YAG-based ceramic is prepared by a solution precursor plasma spray method that includes injecting a precursor solution into a thermal jet, evaporating solvent from the precursor solution droplets, and pyrolyzing the resulting solid to form a YAG-based ceramic that is melted and deposited on a substrate. The thermal barrier coating can include through-coating-thickness cracks that improve the strain tolerance of the coating.

Abstract: A thermal barrier coating that includes a YAG-based ceramic is prepared by a solution precursor plasma spray method that includes injecting a precursor solution into a thermal jet, evaporating solvent from the precursor solution droplets, and pyrolyzing the resulting solid to form a YAG-based ceramic that is melted and deposited on a substrate. The thermal barrier coating can include through-coating-thickness cracks that improve the strain tolerance of the coating.

Abstract: Amorphous mixed metal oxides are used as a feedstock for thermal spray coating. Compared to thermal spray coating methods utilizing crystalline metal oxide feedstocks, the present method reduces energy consumption and expands the range of feedstock chemical compositions. The present method also produces coatings with improved chemical homogeneity. Methods of preparing the amorphous mixed metal oxides are also described.

Abstract: Amorphous mixed metal oxides are used as a feedstock for thermal spray coating. Compared to thermal spray coating methods utilizing crystalline metal oxide feedstocks, the present method reduces energy consumption and expands the range of feedstock chemical compositions. The present method also produces coatings with improved chemical homogeneity. Methods of preparing the amorphous mixed metal oxides are also described.

Abstract: A thermal spray process comprises injecting precursor solution droplets into the hot zone of the thermal spray flame. Also described are materials resulting from the process.

Abstract: A thermal spray process comprises injecting precursor solution droplets into the hot zone of the thermal spray flame. Also described are materials resulting from the process.

Abstract: A contiguous duplex microstructured material comprises a nanostructured material having two structural states, for example, a duplex microstructured coating. One state comprises substantially nanostructured features, while the second state substantially comprises microstructured features. A duplex nanostructured coating can be made by thermal spraying a reconstituted nanostructured material onto a substrate under conditions effective to form a coating comprising more than one structural state.

Abstract: A nickel-based single crystal gas turbine component (30) having a low angle boundary (34) with improved material properties resulting from retained gamma/gamma prime eutectic phase at the low angle boundary. The coarse eutectic phase nodules roughen the grain boundary, reduce the slip distance and disperse concentrated planar slip in the vicinity of the boundary. As a result, the allowable angle of misorientation at the boundary may be increased to greater than 6° for the most highly stressed or critical areas of the component, thereby reducing the amount of scrap material and lowering the cost of manufacturing of a single crystal gas turbine component.

Abstract: A contiguous duplex microstructured material comprises a nanostructured material having two structural states, for example, a duplex microstructured coating. One state comprises substantially nanostructured features, while the second state substantially comprises microstructured features. A duplex nanostructured coating can be made by thermal spraying a reconstituted nanostructured material onto a substrate under conditions effective to form a coating comprising more than one structural state.

Abstract: A contiguous duplex microstructured material comprises a nanostructured material having two structural states, for example, a duplex microstructured coating. One state comprises substantially nanostructured features, while the second state substantially comprises microstructured features. A duplex nanostructured coating can be made by thermal spraying a reconstituted nanostructured material onto a substrate under conditions effective to form a coating comprising more than one structural state.

Abstract: A thermal spray process comprises injecting precursor solution droplets into the hot zone of the thermal spray flame. Also described are materials resulting from the process.