Abstract: Disclosed herein is an erosion and corrosion resistant coating comprising a metallic binder, a plurality of hard particles, and a plurality of sacrificial particles. Also disclosed is a method of improving erosion and corrosion resistance of a metal component comprising disposing on a surface of the metal component the foregoing erosion and corrosion resistant coating comprising, and a metal component comprising a metal component surface and the foregoing erosion and corrosion resistant coating comprising a first surface and a second surface opposite the first surface, wherein the first surface is disposed on the metal component surface.

Abstract: A coating composition includes a cermet material having metal carbide phase particles with an average size of less than 5 microns. The coating has an average surface roughness of less than approximately 5 microns. A system for applying a coating to a substrate includes a spray gun configured for use with a high velocity oxygen or high velocity air fuel system. The system further includes a cermet material supplied to the spray gun, wherein the cermet material includes at least approximately 34 percent by weight of a metal carbide phase having an average particle size of less than or equal to approximately 5 microns. The metal carbide phase is dispersed in a liquid selected from the group consisting of water, alcohol, an organic combustible liquid, or an organic incombustible liquid.

Abstract: A protective coating system for metal components includes a superalloy metal substrate, such as a component of a gas turbine. A single layer bond coat is applied to the superalloy metal substrate in a thermal spray process from a homogeneous powder composition having a particle size distribution wherein about 90% of the particles by volume are within a range of about 10 ?m to about 100 ?m. The percentage of particles within any 10 ?m band within the range does not exceed about 20% by volume, and the percentage of particles within any two adjacent 10 ?m bands within the range does not deviate by more than about 8% by volume.

Abstract: A protective coating system for metal components includes a superalloy metal substrate, such as a component of a gas turbine. A single layer bond coat is applied to the superalloy metal substrate in a thermal spray process from a homogeneous powder composition having a particle size distribution wherein about 90% of the particles by volume are within a range of about 10 pan to about 100 ?m. The percentage of particles within any 10 ?m band within the range does not exceed about 20% by volume, and the percentage of particles within any two adjacent 10 ?m bands within the range does not deviate by more than about 8% by volume.

Abstract: In one embodiment, a protective coating may be electrostatically applied to a rotary machine component. The powder coating includes an electrically conductive sacrificial base coat and a ceramic oxide erosion resistant top coat.

Abstract: A coating composition is described, having a first coating layer which includes a nickel-chromium matrix in which metal carbide particles are dispersed; and a hard, dense second coating layer disposed over the first coating layer. The second coating layer is formed from a metal nitride-type material, and has an average roughness of less than about 80 micro-inches (Ra). Related articles and processes are also disclosed.

Abstract: A coating composition is described, having a first coating layer which includes a metallic matrix in which metal carbide particles are dispersed; and a hard, dense second coating layer disposed over the first coating layer. The second coating layer is formed from a metal nitride-type material, and has an average roughness of less than about 80 micro-inches (Ra). Related articles and processes are also disclosed.

Abstract: Disclosed herein is an erosion and corrosion resistant coating comprising a metallic binder, a plurality of hard particles, and a plurality of sacrificial particles. Also disclosed is a method of improving erosion and corrosion resistance of a metal component comprising disposing on a surface of the metal component the foregoing erosion and corrosion resistant coating comprising, and a metal component comprising a metal component surface and the foregoing erosion and corrosion resistant coating comprising a first surface and a second surface opposite the first surface, wherein the first surface is disposed on the metal component surface.

Abstract: A method of forming a composite powder coating comprises depositing multiple layers of a powder coating composition onto a substrate, wherein adjacent layers are formed of a different powder coating composition; and curing the multiple layers of the powder coating composition in a single thermal curing step. The layers can be used to protect power generation equipment from aqueous corrosion, particle erosion, slurry erosion, fretting, and foulig.