Abstract: Nuclear reactor components are treated with thermal methods to increase wear resistance. Example treatments include thermal treatments using particulate or powderized materials to form a coating. Methods can use cold spray, with low heat and high velocities to blast particles on the surface. The particles impact and mechanically deform, forming an interlocking coating with the surface and each other without melting or chemically reacting. Materials in the particles and resultant coatings include metallic alloys, ceramics, and/or metal oxides. Nuclear reactor components useable with methods of increased wear resistance include nuclear fuel rods and assemblies containing the same. Coatings may be formed on any desired surface, including fuel rod positions where spacer contact and fretting is most likely.

Abstract: Nuclear reactor components are treated with thermal methods to increase wear resistance. Example treatments include thermal treatments using particulate or powderized materials to form a coating. Methods can use cold spray, with low heat and high velocities to blast particles on the surface. The particles impact and mechanically deform, forming an interlocking coating with the surface and each other without melting or chemically reacting. Materials in the particles and resultant coatings include metallic alloys, ceramics, and/or metal oxides. Nuclear reactor components useable with methods of increased wear resistance include nuclear fuel rods and assemblies containing the same. Coatings may be formed on any desired surface, including fuel rod positions where spacer contact and fretting is most likely.

Abstract: A solid oxide fuel cell is disclosed. The fuel cell includes a porous anode, formed of finely-dispersed nickel/stabilized-zirconia powder particles. The particles have an average diameter of less than about 300 nanometers. They are also characterized by a tri-phase length of greater than about 50 ?m/?m3. A solid oxide fuel cell stack is also described, along with a method of forming an anode for a solid oxide fuel cell. The method includes the step of using a spray-agglomerated, nickel oxide/stabilized-zirconia powder to form the anode.

Abstract: Nuclear reactor components are treated with thermal methods to increase wear resistance. Example treatments include thermal treatments using particulate or powderized materials to form a coating. Methods can use cold spray, with low heat and high velocities to blast particles on the surface. The particles impact and mechanically deform, forming an interlocking coating with the surface and each other without melting or chemically reacting. Materials in the particles and resultant coatings include metallic alloys, ceramics, and/or metal oxides. Nuclear reactor components usable with methods of increased wear resistance include nuclear fuel rods and assemblies containing the same. Coatings may be formed on any desired surface, including fuel rod positions where spacer contact and fretting is most likely.

Abstract: Nuclear reactor components are treated with thermal methods to increase wear resistance. Example treatments include thermal treatments using particulate or powderized materials to form a coating. Methods can use cold spray, with low heat and high velocities to blast particles on the surface. The particles impact and mechanically deform, forming an interlocking coating with the surface and each other without melting or chemically reacting. Materials in the particles and resultant coatings include metallic alloys, ceramics, and/or metal oxides. Nuclear reactor components usable with methods of increased wear resistance include nuclear fuel rods and assemblies containing the same. Coatings may be formed on any desired surface, including fuel rod positions where spacer contact and fretting is most likely.

Abstract: A coating method is disclosed including forming a first layer on a substrate and forming a second layer on the first layer. Forming the first layer includes applying virgin powder particles containing at least one rare-earth doped ceramic oxide onto the substrate. Forming the second layer includes applying recycled powder particles containing the at least one rare-earth doped ceramic oxide and at least one extraneous material onto the first layer. Another coating method is disclosed including mixing the virgin powder particles with the recycled powder particles to form a mixture of powder particles, and applying the mixture of powder particles onto the substrate. A coated article is disclosed including a substrate and a coating on the substrate, the coating including virgin powder particles of at least one rare-earth doped ceramic oxide and recycled powder particles including the at least one rare-earth doped ceramic oxide and at least one extraneous material.

Abstract: A compressor blade for use in a compressor section of a gas turbine engine, comprising: a martensitic stainless steel compressor blade and an abrasive coating having an anodic component. The compressor blade has a blade portion, a dovetail portion and a platform portion intermediate the blade portion and the dovetail portion, the blade portion terminating in a tip opposite the dovetail portion. A cobalt-based coating overlies at least the blade portion of the compressor blade. The cobalt-based coating comprises a cobalt based material that includes precipitates of tungsten carbide that provide erosion resistance and particles of a sacrificial metal-based material distributed through the cobalt-based coating that provide galvanic corrosion resistance to the system.

Abstract: An article, such as a bucket, a blade, a nozzle, a vane, a strut, a fuel nozzle, a combustion casing, and a transition piece, the article having a damping coating comprising approximately 8 wt % to approximately 15 wt % Y2O3 and approximately 19 wt % to approximately 28 wt % Ta2O5 with the balanced weight of ZrO2 is presented.

Abstract: Provided is bond coating powder and method of making. The method includes providing a powder including a plurality of parent particles. The method includes providing a plurality of dispersoids. The method includes mechanically alloying the powder and the plurality of dispersoids at ambient temperature. The mechanical alloying operable to provide a selective occupation of the plurality of dispersoids in a grain boundary area of the plurality of parent particles providing the bond coating powder. The plurality of dispersoids occupy about 18 percent to about 30 percent of the grain boundary area of the bond coating powder.

Abstract: A coating composition, a process of applying a coating having a coating composition, and a process of forming a coating composition are disclosed. The coating composition includes an alloy and an oxide component comprising nickel oxide. The process of applying the coating includes cold spraying the coating onto the article. The process of forming the coating composition includes blending and milling the alloy with the oxide component.

Abstract: Nuclear reactor components are treated with thermal methods to increase wear resistance. Example treatments include thermal treatments using particulate or powderized materials to form a coating. Methods can use cold spray, with low heat and high velocities to blast particles on the surface. The particles impact and mechanically deform, forming an interlocking coating with the surface and each other without melting or chemically reacting. Materials in the particles and resultant coatings include metallic alloys, ceramics, and/or metal oxides. Nuclear reactor components usable with methods of increased wear resistance include nuclear fuel rods and assemblies containing the same. Coatings may be formed on any desired surface, including fuel rod positions where spacer contact and fretting is most likely.

Abstract: A coated article, a process of coating an article, and a process of using an article are disclosed. The coated article includes a substrate, a porous coating material, and a thermal barrier coating material. The porous coating material includes a porosity between about 1 percent and about 20 percent, by volume. The thermal barrier coating material has a thermal conductivity that is lower than a thermal conductivity of the substrate. The porous coating material differs in one or both of composition and microstructure from the thermal barrier coating material. Additionally or alternatively, the porous coating material resists at least one of sintering, densification, and phase destabilization for a predetermined period at a predetermined temperature. The process of coating an article includes applying a coating to form the coated article.

Abstract: A treatment process, an oxide-forming treatment composition, and a treated component are disclosed. The treatment process includes applying an oxide-forming treatment composition to a ceramic coating and heating the oxide-forming treatment composition to form an oxide within the ceramic coating. The oxide-forming treatment composition includes a solute and a corrosion inhibitor. The oxide-forming treatment composition is super-saturated with the corrosion inhibitor. The treated component includes a ceramic coating and one or both of a corrosion inhibitor and an oxide formed by an oxide-forming treatment composition having the corrosion inhibitor. The corrosion inhibitor and the oxide-forming treatment composition are within the ceramic coating.

Abstract: A coating material suitable for use in high temperature environments and capable of providing a damping effect to a component subjected to vibration-induced stresses. The coating material defines a damping coating layer of a coating system that lies on and contacts a substrate of a component and defines an outermost surface of the component. The coating system includes at least a second coating layer contacted by the damping coating layer. The damping coating layer contains a ferroelastic ceramic composition having a tetragonality ratio, c/a, of greater than 1 to 1.02, where “c” is a c axis of a unit cell of the ferroelastic ceramic composition and “a” is either of two orthogonal axes, a and b, of the ferroelastic ceramic composition.

Abstract: A compressor blade for use in a compressor section of a gas turbine engine, comprising: a martensitic stainless steel compressor blade and an abrasive coating having an anodic component. The compressor blade has a blade portion, a dovetail portion and a platform portion intermediate the blade portion and the dovetail portion, the blade portion terminating in a tip opposite the dovetail portion. A cobalt-based coating overlies at least the blade portion of the compressor blade. The cobalt-based coating comprises a cobalt based material that includes precipitates of tungsten carbide that provide erosion resistance and particles of a sacrificial metal-based material distributed through the cobalt-based coating that provide galvanic corrosion resistance to the system.

Abstract: A coated article and a coating application process are disclosed. The coated article includes a metallic surface, a first layer positioned proximal to the metallic surface, the first layer having a first ductility, and a second layer positioned distal from the metallic surface, the second layer having a second ductility. The first ductility is at least about 20% greater than the second ductility. The process includes providing an article, the article comprising a metallic surface, applying a first layer proximal to the metallic surface, the first layer having a first ductility, and applying a second layer distal from the metallic surface, the second layer having a second ductility.

Abstract: Provided is bond coating powder and method of making. The method includes providing a powder including a plurality of parent particles. The method includes providing a plurality of dispersoids. The method includes mechanically alloying the powder and the plurality of dispersoids at ambient temperature. The mechanical alloying operable to provide a selective occupation of the plurality of dispersoids in a grain boundary area of the plurality of parent particles providing the bond coating powder. The plurality of dispersoids occupy about 18 percent to about 30 percent of the grain boundary area of the bond coating powder.

Abstract: An enclosure system is provided having a shroud configured to cover at least a portion of a shaft. The shroud includes an input port and an output port. The input port is configured to accept at least one of a coating tool and an abrasive supplying tool. The output port is connected to a vacuum system.

Abstract: A coating composition, a process of applying a coating having a coating composition, and a process of forming a coating composition are disclosed. The coating composition includes an alloy and an oxide component comprising nickel oxide. The process of applying the coating includes cold spraying the coating onto the article. The process of forming the coating composition includes blending and milling the alloy with the oxide component.

Abstract: Different plasma spray guns have differing current and voltage requirements for their operation. The spray guns generally fall into low voltage high current and high voltage low current types. The power requirements of the guns vary greatly in terms of overall power ranging from few tens of kilowatts to few hundreds of kilowatts. The guns also have wide ranging requirements for voltage and current. A power delivery unit is described in which the unit is capable of delivering the wide range of power as well as the wide ranges of voltage and current. A plasma spray system with such power delivery unit can universally operate both the low voltage high current and high voltage low voltage spray gun types. Such system can reduce capital and operation costs since shops need not maintain separate and incompatible plasma spray systems.