Abstract: A solar cell having foil electrodes. Specifically, a metal foil is implemented to form electrodes providing a reduced electron path from a dye-sensitized semiconductor material to the electrodes. In one embodiment, nanowires extending from the substrate on which the solar cell is formed are provided. In another embodiment, cavities are formed in a sheet of conductive foil by oxidation, thereby forming a semiconductive material. The semiconductive material is sensitized with a dye and an electrolyte solution is disposed in the cavities, thereby forming an array of dye-sensitized solar cells.

Abstract: A water-cooled stator bar clip for electrical generators and a method for applying a corrosion-resistant protective coating, preferably Sc, Ti, Cr, Zr, Nb, Mo, Hf, Ta, W, Ni, and Al, and their alloys or oxides to existing stator bar end fittings in order to significantly reduce the possibility of leaks through the brazed connections of the copper stator bar end connections. The coatings can be applied locally using various known physical vapor deposition (“PVD”), chemical vapor deposition (“CVD”) or other direct coating techniques known in the art. For example, the coatings can be applied using ion plasma deposition, sputtering or wire arc techniques (all PVD processes) or by using electroplating, high velocity oxygen free (“HVOF”) deposition, DC arc or electroless plating. Preferably, the coatings are applied either to new stator bar clips or to existing clips in the field.

Abstract: A water-cooled stator bar clip for electrical generators and a method for applying a corrosion-resistant protective coating, preferably Sc, Ti, Cr, Zr, Nb, Mo, Hf, Ta, W, Ni, and Al, and their alloys or oxides to existing stator bar end fittings in order to significantly reduce the possibility of leaks through the brazed connections of the copper stator bar end connections. The coatings can be applied locally using various known physical vapor deposition (“PVD”), chemical vapor deposition (“CVD”) or other direct coating techniques known in the art. For example, the coatings can be applied using ion plasma deposition, sputtering or wire arc techniques (all PVD processes) or by using electroplating, high velocity oxygen free (“HVOF”) deposition, DC arc or electroless plating. Preferably, the coatings are applied either to new stator bar clips or to existing clips in the field using a known pencil coater technique.

Abstract: A PVD process and apparatus (120) for depositing a coating (132) from multiple sources (110, 111) of different materials. The process and apparatus (120) are particulaity intended to deposit a beta-nickel aluminide coating (132) containing one or more elements whose vapor pressures are lower than NiAl. The PVD process and apparatus (120) entail feeding at least two materials (110, 111) into a coating chamber (122) and evaporating the materials (110, 111) at different rates from separate molten pools (114, 115) thereof. Articles (130) to be coated are suspended within the coating chamber (122), and transported with a support apparatus (118) relative to the two molten pools (114, 115) so as to deposit a coating (132) with a controlled composition that is a mixture of the first and second materials (110, 111).

Abstract: A method of introducing small amounts of a refractory element into a vapor deposition coating. A second material (30), containing at least two elements which are desired to be deposited as a coating on a base material, has placed over it a first material (20) substantially comprising such two elements and a refractory element. The first material (20) is adapted to permit transport of the at least two elements in the second material (30) through the first material (20) when the first (20) and second (30) material are in a molten state and in touching contact with the other so as to permit evaporation of the two elements and the refractory element from an exposed surface. Heat is supplied to the first (20) and second (30) materials to permit evaporation of the at least two elements of second material (30) and the refractory element in the first material (20), and the resulting vapors are condensed as a deposit on a base material (50).

Abstract: An apparatus for cathodic arc coating. The apparatus includes: a vacuum chamber which includes: an anode; a power supply; and a cathode target assembly connected to the power supply. The cathode target assembly includes a cathode target having an interference fit stud with a threadless distal end. In the preferred embodiment, the distal end of the threadless cathode target also includes a pre-determined surface texture and a cooling block in contact with the cathode target.

Abstract: A method for heat treating titanium-alloy articles in a vacuum furnace includes a step of first determining, for a first set of titanium articles in a first vacuum furnace and for a first set of heat treatment conditions, a minimum surface area of the first set of titanium articles associated with an acceptable alpha case formation for the first set of titanium articles. There is a second determining, for a second set of titanium articles in a second vacuum furnace and for a second set of heat treatment conditions, of a minimum surface area of a second set of titanium articles associated with an acceptable alpha case formation for the second set of titanium articles, responsive to the value of the minimum surface area of the first set of titanium articles.

Abstract: A method of depositing a coating at a substrate via ion plasma deposition comprises subjecting a cathode and the substrate to a vacuum environment, applying a bias voltage to the substrate, supplying a current to the cathode, operating a cathodic arc from the cathode, and depositing an alloy coating from the cathode at a surface of the substrate. The cathode comprises a nickel-aluminum family alloy. The coating deposited is a nickel-aluminum family alloy. A cathode for an ion plasma deposition process comprises a body fabricated from a first composition, and a plug disposed at the body, the plug being fabricated from a second composition. A nickel-aluminum family cathode having a tapered outer surface comprises a body tapered along a longitudinal axis thereof and a ring having a tapered inner surface at which the tapered outer surface of the body is received.

Abstract: A solar cell having foil electrodes. Specifically, a metal foil is implemented to form electrodes providing a reduced electron path from a dye-sensitized semiconductor material to the electrodes. In one embodiment, nanowires extending from the substrate on which the solar cell is formed are provided. In another embodiment, cavities are formed in a sheet of conductive foil by oxidation, thereby forming a semiconductive material. The semiconductive material is sensitized with a dye and an electrolyte solution is disposed in the cavities, thereby forming an array of dye-sensitized solar cells.

Abstract: A method for heat treating titanium-alloy articles in a vacuum furnace includes a step of first determining, for a first set of titanium articles in a first vacuum furnace and for a first set of heat treatment conditions, a minimum surface area of the first set of titanium articles associated with an acceptable alpha case formation for the first set of titanium articles. There is a second determining, for a second set of titanium articles in a second vacuum furnace and for a second set of heat treatment conditions, of a minimum surface area of a second set of titanium articles associated with an acceptable alpha case formation for the second set of titanium articles, responsive to the value of the minimum surface area of the first set of titanium articles.

Abstract: A method of introducing small amounts of a refractory element into a vapor deposition coating. A second material (30), containing at least two elements which are desired to be deposited as a coating on a base material, has placed over it a first material (20) substantially comprising such two elements and a refractory element. The first material (20) is adapted to permit transport of the at least two elements in the second material (30) through the first material (20) when the first (20) and second (30) material are in a molten state and in touching contact with the other so as to permit evaporation of the two elements and the refractory element from an exposed surface. Heat is supplied to the first (20) and second (30) materials to permit evaporation of the at least two elements of second material (30) and the refractory element in the first material (20), and the resulting vapors are condensed as a deposit on a base material (50).

Abstract: A predominantly beta-phase NiAl overlay coating for use as an environmental coating or a TBC bond coat for articles used in hostile thermal environments, such as components of a gas turbine engine. The coating contains up to about 4 atomic percent hafnium, such as in excess of 1.0 atomic percent hafnium. The coating may also contain about 2 to about 15 atomic percent chromium.

Abstract: A system and method for repairing defects such as bumper holes, cracks, freckles and inclusions, in a cast article, such as a turbine component. The system comprises a device for locating a defect in a cast article, a repair material that is disposable at a defect site, at least one heat source capable of heating the repair material and a portion of the cast article to a molten state. The method of using the system comprises locating a defect in the cast article, providing a repair material to the defect site, melting the repair material and cast article at the defect site, and cooling the molten repair material and portion of the casting article such that they resolidify and fuse together. The method may further comprise removing a portion of the cast article at the defect site, removal of excess repair material and inspecting the cast article following repair of the defect.

Abstract: A sensor for measuring electrochemical corrosion potential, and a method for manufacturing a sensor, the sensor comprising a tubular ceramic probe having a closed tip at one end, the probe at least partially filled with a powder comprising metal and metal oxide; a metal support tube having one end receiving an opposite end of the probe, and joined thereto by a braze joint therewith; an electrical conductor extending through the support tube and into the probe, and having an end buried in the powder for electrical contact therewith; and a protective band bridging the probe and tube at the joint for sealing thereof, the protective band consisting essentially of a metallic coating.

Abstract: An apparatus for cathodic arc coating. The apparatus includes: a vacuum chamber which includes an anode; a power supply; and a cathode target assembly connected to the power supply. The cathode target assembly includes a cathode target and a target holder. In the preferred embodiment, a conductive interlayer is located between the cathode target and the target holder, and a cooling block is in contact with the cathode target.

Abstract: A method of repairing a defect in a casting or cast article, where the defect comprises at least one of a manufacturing, intentional, or service-related defect. The cast article can comprise a casting core and a casting, the casting core comprising a bumper that creates a thin region, namely the defect. One method of repairing the bumper hole defect comprises locating the defect area in the cast article; removing an area of the casting at the defect area; removing an area of the casting core including the bumper at the defect area, where the removing the area of the casting at the defect area and removing an area of the casting core including the bumper at the defect area create a hole; positioning repair material in the hole; heating the defect area, the repair material and the area of the casting at the defect area to melt the repair material and area of the casting at the defect area into a molten material; and re-solidifying the molten material to form a repaired casting.

Abstract: A method of introducing small amounts of a refractory element into a vapor deposition coating. A second material (30), containing at least two elements which are desired to be deposited as a coating on a base material, has placed over it a first material (20) substantially comprising such two elements and a refractory element. The first material (20) is adapted to permit transport of the at least two elements in the second material (30) through the first material (20) when the first (20) and second (30) material are in a molten state and in touching contact with the other so as to permit evaporation of the two elements and the refractory element from an exposed surface. Heat is supplied to the first (20) and second (30) materials to permit evaporation of the at least two elements of second material (30) and the refractory element in the first material (20), and the resulting vapors are condensed as a deposit on a base material (50).

Abstract: A sensor for measuring electrochemical corrosion potential, and a method for manufacturing a sensor, the sensor comprising a tubular ceramic probe having a closed tip at one end, the probe at least partially filled with a powder comprising metal and metal oxide; a metal support tube having one end receiving an opposite end of the probe, and joined thereto by a braze joint therewith; an electrical conductor extending through the support tube and into the probe, and having an end buried in the powder for electrical contact therewith; and a protective band bridging the probe and tube at the joint for sealing thereof, the protective band consisting essentially of a metallic coating.

Abstract: A predominantly beta-phase NiAl overlay coating for use as an environmental coating or a TBC bond coat for articles used in hostile thermal environments, such as components of a gas turbine engine. The coating contains up to about 4 atomic percent hafnium, such as in excess of 1.0 atomic percent hafnium. The coating may also contain about 2 to about 15 atomic percent chromium.

Abstract: A PVD process and apparatus (120) for depositing a coating (132) from multiple sources (110,111) of different materials. The process and apparatus (120) are particularly intended to deposit a beta-nickel aluminide coating (132) containing zirconium, hafnium, yttrium and/or cerium, whose vapor pressures are sufficiently lower than NiAl to require a different evaporation rate in order to achieve higher deposition rates and better control of the coating chemistry. The PVD process and apparatus (120) entail feeding at least two materials (110,111) into a coating chamber (122) and melting the materials (110,111) at different rates to form separate molten pools (114,115) thereof. Articles (130) to be coated are suspended within the coating chamber (122), and transported with a support apparatus (118) relative to the two molten pools (114,115) so as to deposit a coating (132) with a controlled composition that is a mixture of the first and second materials (110,111).