Abstract: A thermal spray powder consists of nickel, chromium and carbon. The chromium consists of a first portion and a second portion, the nickel being alloyed with the first portion in an alloy matrix. The second portion and the carbon are combined into chromium carbide substantially as Cr3C2 or Cr7C3 or a combination thereof, with the chromium carbide being in the form of precipitates between 0.1 &mgr;m and 5 &mgr;m distributed uniformly in the alloy matrix.

Abstract: A powder of dicalcium silicate is made by spray drying calcia and silica with incorporation of sodium and phosphorus or stabilized zirconia. The spray dried powder is sintered to form a thermal spray powder. Sprayed coatings have a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coatings are stable in thermal cycling and a hot corrosive environment.

Abstract: A thermal spray powder consists of nickel, chromium and carbon. The chromium consists of a first portion and a second portion, the nickel being alloyed with the first portion in an alloy matrix. The second portion and the carbon are combined into chromium carbide substantially as Cr.sub.3 C.sub.2 or Cr.sub.7 C.sub.3 or a combination thereof, with the chromium carbide being in the form of precipitates between 0.1 .mu.m and 5 .mu.m distributed uniformly in the alloy matrix.

Abstract: A granular composition is applied to tips of rotor blades utilized in a gas turbine engine wherein the blade tips rub against an abradable ceramic layer. Individual grains each have a core of silicon carbide and a layer of aluminum nitride on the core. A layer of a cladding metal may be bonded to the aluminum nitride. The composition also may include particles of cubic boron nitride and/or particles of metal alloy blended with the grains of silicon carbide.

Abstract: A composite thermal spray powder, for producing abradable coatings, is substantially in the form of clad particles each of which has a core particle of boron nitride and subparticles of aluminum-silicon alloy. The subparticles are bonded to the core particle with an polymeric binder.

Abstract: A composite thermal spray powder for abradable coatings is formed as homogeneously agglomerated particles. Each agglomerated particle consists of pluralities of subparticles of boron nitride and subparticles of aluminum or aluminum alloy bonded with an organic binder.

Abstract: Manufacture of glass mold plungers utilizes a thermal spray gun having combustion chamber with an open channel for propelling combustion products into the ambient atmosphere at supersonic velocity. The method comprises injecting into the chamber a combustible mixture of combustion gas and oxygen at a pressure in the chamber of at least two atmospheres above ambient atmospheric pressure, feeding into the chamber a powder comprising self-fluxing alloy particles, and combusting the combustible mixture in the chamber means whereby a supersonic spray stream containing the powder is propelled through the open channel. The spray stream is directed toward a glass mold plunger substrate such as to produce a coating thereon which is ground and polished. The coating may be fused prior to grinding.

Abstract: A cobalt bonded tungsten carbide powder is produced by a method comprising preparing a mixture consisting of a first tungsten carbide powder having a particle size of -5 microns, a second tungsten carbide powder having a particle size of -44+10 microns, a cobalt powder having a particle size of -5 microns and a carbon powder having a particle size of -1 micron. The mixture has proportions, by weight totaling 100%, of about 10% to 30% first tungsten carbide, 40% to 80% second tungsten carbide, 8% to 25% cobalt and 0.5 to 3% carbon. The mixture is processed by compacting, sintering, crushing, and classifying to produce the cobalt bonded tungsten powder in a size range -100+10 microns.

Abstract: A novel iron based alloy is disclosed which is characterized by high resistance to wear and corrosion. The alloy consists essentially of 0 to 40% chromium, 1 to 40% molybdenum, 1 to 15% copper, 0.2 to 5% boron, and 0.01 to 2% carbon; the balance being incidental impurities and at least 30% iron, with the molydenum being at least 10% if the boron is greater than 2%. The alloy is preferably in the form of a powder for thermal spraying, and coatings produced thereby may have an amorphous structure.

Abstract: A hollow sphere ceramic flame spray powder is disclosed. The desired constituents are first formed into agglomerated particles in a spray drier. Then the agglomerated particles are introduced into a plasma flame which is adjusted so that the particles collected are substantially hollow. The hollow sphere ceramic particles are suitable for flame spraying a porous and abradable coating. The hollow particles may be selected from the group consisting of zirconium oxide and magnesium zirconate.