Abstract: An abradable powder composition is includes a metal component, a lubricant component, and a polymer component. A portion of the metal component is wrapped in the lubricant component to achieve high lubricity and abradability. The abradable powder composition can be used to form an abradable seal coating provided for use in a turbo machinery having a housing and a wheel having multiple blades. The housing houses the wheel which rotates therein. The seal coating is formed on the inner walls of housing adjacent where the wheel blades pass during their rotation. When the wheel is rotated such that, the blades contact the seal coating, it is abraded to form a close fit gap. The abradable seal coating preferably does not produce significant wear of the blade tips or transfer abradable material significantly to the blade tips upon being abraded.

Abstract: An abradable powder composition is includes a metal component, a lubricant component, and a polymer component. A portion of the metal component is wrapped in the lubricant component to achieve high lubricity and abradability. The abradable powder composition can be used to form an abradable seal coating provided for use in a turbo machinery having a housing and a wheel having multiple blades. The housing houses the wheel which rotates therein. The seal coating is formed on the inner walls of housing adjacent where the wheel blades pass during their rotation. When the wheel is rotated such that the blades contact the seal coating, it is abraded to form a close fit gap. The abradable seal coating preferably does not produce significant wear of the blade tips or transfer abradable material significantly to the blade tips upon being abraded.

Abstract: An abradable powder composition is includes a metal component, a lubricant component, and a polymer component. A portion of the metal component is wrapped in the lubricant component to achieve high lubricity and abradability. The abradable powder composition can be used to form an abradable seal coating provided for use in a turbo machinery having a housing and a wheel having multiple blades. The housing houses the wheel which rotates therein. The seal coating is formed on the inner walls of housing adjacent where the wheel blades pass during their rotation. When the wheel is rotated such that the blades contact the seal coating, it is abraded to form a close fit gap. The abradable seal coating preferably does not produce significant wear of the blade tips or transfer abradable material significantly to the blade tips upon being abraded.

Abstract: Lubricant-hard-ductile composite coating compositions and methods of making the same are provided. In embodiment, a composite coating composition comprises: a lubricant phase for providing lubrication to a surface; a hard ceramic phase for providing structural integrity and wear resistance to the surface; and a ductile metal phase for providing ductility to the surface.

Abstract: Disclosed herein is a magnetic paste that generally includes a magnetic component and a liquid organic component. The magnetic component includes a plurality of discrete nanoparticles, a plurality of nanoparticle-containing assemblies, or both. Magnetic devices can be formed from the magnetic paste. Methods of making and using the magnetic paste are also described.

Abstract: Methods of the invention allow rapid production of high-porous, large-surface-area nanostructured metal and/or metal oxide at attractive low cost applicable to a wide variety of commercial applications such as sensors, catalysts and photovoltaics.

Abstract: Provided are methods related to preventing hydrocarbon residue buildup in engine, exhaust-gas-system or powertrain components. Prevention is achieved by applying coating of a mixed metal oxide via a suspension plasma spray.

Abstract: The invention provides a method for forming a thermal barrier coating having vertical cracks for improved thermal and mechanical stress tolerance. The method can include depositing a first sub-layer on a substrate at a first temperature T1, followed by depositing a second sub-layer on the first sub-layer at a second temperature T2, wherein T2 is less than T1 such that a temperature gradient having a negative heat flux toward the top of the second sub-layer is created, thereby introducing thermal stress in the sub-layers causing vertical cracks to be formed in the sub-layers. The method then involves repeating steps (a) and (b) for n cycles to form the thermal barrier coating comprising the vertical cracks, wherein n is an integer from 1 to 200.

Abstract: The present invention provides methods for producing a crack-free abradable coating with enhanced adhesion. The methods include the steps of providing a substrate and applying an abradable material to the substrate, either directly or indirectly via one or more additional layers. A critical coating temperature of the abradable material is determined that ensures that the thermal stress level in the abradable material is lower than the tensile strength of the abradable material. The temperature of the abradable material is held at a constant temperature below the critical coating temperature throughout the step of applying the abradable material to the substrate.

Abstract: A patterned inductor includes a conductive path and a nanostructured magnetic composition deposited on the conductive path. The magnetic composition can be screen printed, inkjetted, electrodeposited, spin coated, physical vapor deposited, or chemical vapor deposited onto the conductive path.

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: Lubricant-hard-ductile composite coating compositions and methods of making the same are provided. In embodiment, a composite coating composition comprises: a lubricant phase for providing lubrication to a surface; a hard ceramic phase for providing structural integrity and wear resistance to the surface; and a ductile metal phase for providing ductility to the surface.

Abstract: Thick film magnetic/insulating nanocomposite materials, with significantly reduced core loss, and their manufacture are described. The insulator coated magnetic nanocomposite comprises one or more magnetic components, and an insulating component. The magnetic component comprises nanometer scale particles (about 1 to about 100 nanometers) coated by a thin-layered insulating phase. While the intergrain interaction between the immediate neighboring magnetic nanoparticles separated by the insulating phase provides the desired soft magnetic properties, the insulating material provides high resistivity, which reduces eddy current loss.

Abstract: Superfine ceramic thermal spray feedstock compositions and methods of making and using such compositions are provided. In an embodiment, a thermal spray feedstock composition comprises: a superfine ceramic material comprising grains having an average longest dimension of about 100 nanometers to about 500 nanometers; and a grain growth inhibitor comprising a ceramic oxide different from the superfine ceramic material.

Abstract: Anti-fouling coating compositions and methods of making and using those compositions are provided. In an embodiment, a coating composition comprises ceramic nanoparticles, wherein the coating composition is capable of inhibiting contaminants from adhering to a solid surface.

Abstract: Disclosed herein are molds coated for surface enhancement, methods of making the molds, and methods of casting using such molds. In one embodiment, a mold comprises: a mold member comprising copper; and a coating disposed on at least a portion of a surface of the mold member, wherein the coating has a coefficient of thermal expansion of about 10×10?6/° C. to about 16.5×10?6/° C. and a Vickers Hardness Number of greater than about 500 and less than about 1200 at a temperature of less than or equal to about 600° C.

Abstract: Cored wires having a core comprising agglomerates of superfine particles and/or nanoparticles for thermal spray or overlay weld applications and methods of making the same are provided. Methods of coating a substrate by thermal spraying such as electric arc spraying with such cored wires are also provided. In an embodiment, a cored wire comprises a metallic sheath at least partially surrounding a core comprising agglomerates of superfine particles, nanoparticles, or a combination comprising at least one of the foregoing particles.

Abstract: Methods of making a metallic or cerment coating include suspending solid fine metal or cerment particles in a liquid to form a liquid feedstock and injecting the liquid feedstock into an high-velocity oxygen fuel flame gun to thermally spray the liquid feedstock on a substrate to form a coating thereon.

Abstract: Disclosed herein are medical devices. The medical devices generally include a biocompatible nanostructured ceramic material having an average grain size dimension of about 1 nanometer to about 1000 nanometers, a strain to failure of at least about 1 percent, and a cross-sectional hardness greater than or equal to about 350 kilograms per square millimeter. Also disclosed are methods of making and using the medical devices.