Abstract: This invention relates to coatings for a metal or non-metal substrate comprising (a) a thermal sprayed bondcoat layer applied to the substrate, and (b) a thermal sprayed ceramic layer applied to said bondcoat layer; wherein said coating has a helium leak rate of less than 6×10?6 standard cubic centimeters per second. The thermal sprayed bondcoat layer comprises (i) a thermal sprayed inner layer alloy, and (ii) a thermal sprayed outer layer alloy. The inner layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 50 microns. The outer layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 30 microns to about 100 microns. The coatings are useful for extending the service life under severe conditions, such as those associated with metallurgical vessels' lances, nozzles and tuyeres.

Abstract: This invention relates to coatings for a metal or non-metal substrate comprising (i) a thermal sprayed bondcoat layer applied to the substrate, and (ii) a thermal sprayed ceramic layer applied to the bondcoat layer; wherein said coating has a helium leak rate of less than 6×10?6 standard cubic centimeters per second. The thermal sprayed bondcoat layer comprises an alloy of MCrAlM? wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M? is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof. The alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns. The coatings are useful for extending the service life under severe conditions, such as those associated with metallurgical vessels' lances, nozzles and tuyeres.

Abstract: A hydrogen transport membrane in which a porous ceramic support supports a dense layer of palladium or an alloy of palladium serving as a hydrogen transport material. The ceramic support has a first porous layer and a second porous layer. The first porous layer has a first thickness of about 1 mm, a first set of pores have a first average pore size of between about 10 microns and about 50 microns and a first porosity of about 40 percent by volume. The second porous layer has a second thickness of about 3 microns, a second set of pores having a second average pore size of between about 10 nanometers and about 100 nanometers and a second porosity of about 50 percent by volume. The dense layer has a thickness of about 3 microns.

Abstract: A hydrogen transport membrane in which a porous ceramic support supports a dense layer of palladium or an alloy of palladium serving as a hydrogen transport material. The ceramic support has a first porous layer and a second porous layer. The first porous layer has a first thickness of about 1 mm, a first set of pores have a first average pore size of between about 10 microns and about 50 microns and a first porosity of about 40 percent by volume. The second porous layer has a second thickness of about 3 microns, a second set of pores having a second average pore size of between about 10 nanometers and about 100 nanometers and a second porosity of about 50 percent by volume. The dense layer has a thickness of about 3 microns.

Abstract: A method of forming a hydrogen transport membrane to separate hydrogen from a hydrogen containing feed in which a porous ceramic support is formed to support a dense layer of palladium or an alloy of palladium serving as a hydrogen transport material. Isolated deposits of palladium, a palladium alloy or a component of such alloy are produced on a surface of the porous ceramic support that bridge pores within the porous ceramic support without penetrating the pores and without bridging regions of the surface defined between the pores. The isolated deposits of the metal are produced by an electroless plating process.

Abstract: This invention relates to coatings for a metal or non-metal substrate comprising (a) a thermal sprayed bondcoat layer applied to said substrate, said bondcoat layer comprising: (i) a thermal sprayed inner layer comprising an inner layer alloy of MCrAlM? wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M? is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof; and (ii) a thermal sprayed outer layer comprising an outer layer alloy of MCrAlM? wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M? is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and (b) a thermal sprayed ceramic layer applied to said bondcoat layer. The coatings are useful for extending the service life under severe conditions, such as those associated with metallurgical vessels' lances, nozzles and tuyeres.

Abstract: This invention relates to coatings for a metal or non-metal substrate comprising (i) a thermal sprayed bondcoat layer applied to said substrate comprising an alloy of MCrAlM? wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M? is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and wherein M comprises from about 35 to about 80 weight percent of said alloy, Cr comprises from about 15 to about 45 weight percent of said alloy, Al comprises from about 5 to about 30 weight percent of said alloy, and M? comprises from about 0.01 to about 1.0 weight percent of said alloy, said alloy thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns, said bondcoat having a surface roughness of at least 200 micro-inches, and said bondcoat having a thermal expansion of about 6.5 millimeters per meter or less between a temperature of from about 25° C. to about 525° C.

Abstract: A cold isopressing method and mold for compacting a granular ceramic material in which the granular ceramic material is introduced into a cylindrical pressure bearing element of an isopressing mold. The cylindrical pressure bearing element is sufficiently rigid so as to maintain its shape during the introducing of the granular ceramic material. Such element is also sufficiently resilient in a radial direction thereof to deform and bear against the granular ceramic material upon the application of the hydrostatic pressure and to substantially return to its original shape upon the relaxation of the hydrostatic pressure, thereby to allow retraction of the cylindrical pressure bearing element from the granular ceramic material after compaction. In a further aspect, an isopressing method and mold is provided in which the cylindrical pressure bearing element thereof is provided with an enlarged end bore to form an enlarged end section in the finished ceramic tube for sealing purposes.

Abstract: A cold isopressing method and mold for compacting a granular ceramic material in which the granular ceramic material is introduced into a cylindrical pressure bearing element of an isopressing mold. The cylindrical pressure bearing element is sufficiently rigid so as to maintain its shape during the introducing of the granular ceramic material. Such element is also sufficiently resilient in a radial direction thereof to deform and bear against the granular ceramic material upon the application of the hydrostatic pressure and to substantially return to its original shape upon the relaxation of the hydrostatic pressure, thereby to allow retraction of the cylindrical pressure bearing element from the granular ceramic material after compaction. In a further aspect, an isopressing method and mold is provided in which the cylindrical pressure bearing element thereof is provided with an enlarged end bore to form an enlarged end section in the finished ceramic tube for sealing purposes.

Abstract: A cold isopressing method in which first and second layers of at least two layers are formed within an isopressing mold and the second of the layers is isostatically pressed against the first of the layers to compact the second layer. The layers can be formed from different materials, for instance granular materials or slurries. Each layer can additionally have different levels of materials. The granular materials can have pore formers to produce intermediate porous layers. Channel forming materials can be positioned between layers during isopressing. Alternatively, the first layers can be preformed by extrusion, slip casting or injection isopressing molding. One or more of the layers can have two or more regions of different ceramic materials.