Abstract: When forming a beam shaped body by deposition using a focused ion beam device on the end of a sample, the present invention adopts a beam shaped film pattern formation method for irradiating the focused ion beam to a narrow strip shaped region from an open end of the sample to an outer space, and depositing a beam shaped film on the narrow strip shaped region, and sequentially shifting the irradiation region in a tip end direction to cause formation of a beam shaped body by growth of thin deposition layers, and causing formation of a deposition film of desired thickness on the thin deposition layers on the beam shaped body.

Abstract: A stationary shroud of a gas turbine engine made of a base metal is repaired by removing any damaged material from a flow-path region of the stationary shroud to leave an initially exposed base-metal flow-path surface; and applying a base-metal restoration overlying the initially exposed flow-path surface. The base-metal restoration is applied by furnishing a source of a structural material that is compatible with the base metal, in a form such as a powder or a wire, and depositing the source of the structural material overlying the initially exposed base-metal flow-path surface of the stationary shroud by laser cladding to form a repaired base-metal flow-path surface. An environmentally resistant rub coating may be applied overlying the base-metal restoration.

Abstract: A process for inhibiting the fouling of a substrate in a fouling environment, which comprises forming on the substrate, before exposure to the environment, a coating comprising a film-forming polymer (A) carrying unreacted curable silicon-containing functional groups providing latent reactivity, and thereafter applying a layer comprising a curable polymeric fouling-inhibiting material (B), more especially a curable polysiloxane or a curable flourine-containing polymer, and bonding the applied layer to the coating by a condensation curing reaction involving the unreacted functional groups thereon. The initial coating can be applied over a range of worn or damaged anti-fouling coatings. The sequential application of layers is a simpler, more flexible and more controllable procedure than is offered by complex systems designed to produce outer siloxane-rich regions. Relatively long periods are achievable.

Abstract: A method for coating an article includes preparing a coating precursor paint including aluminum-containing pigment particles, a temporary organic binder comprising an acrylic, and a solvent for the temporary organic binder. The coating precursor paint is applied to a surface of the article and thereafter heated to a temperature of from about 1200° F. to about 2100° F. in a non-oxidizing environment.

Abstract: A process of removing deposits from through-holes in a component, such as metallic bond coat and ceramic materials from cooling holes in an air-cooled gas turbine engine. The process is particularly effective in removing a TBC material deposited in a cooling hole of a component as a result of depositing a coating of the TBC material on a surface of the component, in which the deposit is removed from the cooling hole without damaging the cooling hole or the TBC coating surrounding the cooling hole on the coated surface of the component. A preferred feature is that the cooling hole, including the entrance to the hole at a surface of the component opposite the coated surface and the coating surrounding the exit of the hole at the coated surface, exhibits improved surface characteristics that increase the discharge coefficient of the cooling hole, as evidenced by an increase in the effective area of the cooling hole.

Abstract: The invention relates first of all to a method for covering areas of damaged protective coating on containers or the like, in which, according to the invention, protective coating material is stamped on to the zone in which the damaged areas occur. The invention also describes an apparatus for carrying out the method in which a carrier unit is provided for stamping protective coating material on to the damaged area. Apparatus is provided for positioning the carrier unit with respect to the container.

Abstract: A method for applying at least one bond coating on a surface of a metal-based substrate is described. A foil of the bond coating material is first attached to the substrate surface and then fused thereto, e.g., by brazing. The foil is often initially prepared by thermally spraying the bond coating material onto a removable support sheet, and then detaching the support sheet. Optionally, the foil may also include a thermal barrier coating applied over the bond coating. The substrate can be a turbine engine component.

Abstract: A composite structural laminate plate suitable for building maritime vessels or for building civil structures such as double hull oil tankers, bulk carriers, barges decks for roll-on roll-off ferries, orthotropic bridge decks or for building any structural application in which the traditional method of construction uses stiffened steel plates. The laminate has two facing metal layers that are structurally bonded to a polyurethane elastomer core which may have steel or rigid foam void sections embedded within. The laminate provides equivalent inplane and transverse stiffness and strength, reduces fatigue problems, minimizes stress concentrations, improves thermal and acoustical insulation, and provides vibration control. The laminate provides a structural system that acts as a crack arrest layer and that can join two dissimilar metals without welding or without setting up a galvanic cell.

Abstract: Slag coating is accomplished by blowing a gas from a top-blown lance such that slag is splashed uniformly onto the barrel and throat near the trunnion of the converter; the lance height is adjusted to 0.7-3.0 m and the gas flow rate is adjusted to 250-600 Nm3/min and, after gas blowing, the remaining molten slag is incorporated with a slag solidifier containing MgO or CaO and the molten slag is splashed toward the desired part of the converter wall that needs repair.

Abstract: There is disclosed a masking foam tape adapted for use in spraying automobile doors and like openings to prevent penetration of spray through the unsealed gap between the door and the door surround. In one embodiment, the masking foam tape includes an elongate substantially rectangular section having a major dimension at least twice but not more than four times its minor dimension and having at one end of its elongate section adhesive for attachment at the opening. At the opposite end, the elongate section can be tapered and free of adhesive.

Abstract: A method for adjusting the size of cooling holes of a gas turbine component is disclosed in which the component is shielded with an easily removable and non- conductive shielding material without shielding the cooling holes themselves. The cooling holes are then coated by a galvanic process and the size of the cooling holes is restored to within manufacturing tolerances. The shielding material is removed and, subsequently, a heat treatment for securing a bonding of the metallic coating is applied.

Abstract: This invention pertains to the repair of parts comprising metals, and surfaces and coatings of these parts using reactive metals coating processes. Processes such as chemical vapor deposition (CVD), physical vapor deposition (PVD), plasma spray, and reactive coating (boronizing, carburizing, nitridizing, carbonitridizing, etc.) are known for producing durable coatings or surfaces on metal parts, and the present invention provides a means to spot-repair these coatings or surfaces without excessive buildup of repair material on undamaged areas.

Abstract: A discharge surface treatment method with which discharge is caused to occur between an electrode and a workpiece to generate energy to form a coating on a surface of the workpiece, and method therefore. An electrode is made by combining a hard material, such as WC, and a soft material, such as Co. The hard and soft materials are mixed and compressed into a green compact. The green compact is baked in a vacuum furnace at a temperature which is below the sintering temperature but high enough to melt the soft material. The melted soft material fills the gaps between the particles of the hard material, resulting in an electrode having a texture similar to chalk called incomplete-sintering. The electrode is then used in discharge surface treatment.

Abstract: The present invention provides a method for coating bare, untreated metal substrates wherein a coating composition comprising one or more particularly defined additives is applied directly to a bare metal substrate which has not been chemically and/or mechanically altered. The invention provides a method of coating a bare untreated metal substrate. The method requires the steps of (i) providing a bare, untreated metal substrate, the substrate being substantially free of mechanical and/or chemical alterations, (ii) applying a two-component urethane coating composition directly to the bare, untreated metal substrate so as to make a coated metal substrate, and (iii) sanding at least a portion of the coated metal substrate within one hour from the time the two-component urethane coating composition was applied to the bare, untreated metal substrate. The resulting coated metal substrate has an initial adhesion loss of less than 20% as measured by a cross hatch adhesion test per ASTM D-3359 93.

Abstract: A HVOF process is used for applying brazing materials to repair surfaces of a substrate such as a turbine blade. The brazing material is applied in powdered form and is free of binders and adhesives. The brazing materials may be any one or more of a nickel based, cobalt based or ferrous based high temperature brazing material. Alloys of these elements may be used together with a temperature depressing melting point element such as boron or silicon.

Abstract: This invention relates to a method of repairing a moisture barrier separating a paper machine dryer drum from the dryer journal. Such processes of this type, generally, involve filling the cavity between the dryer drum steam intake pipe and the dryer journal with a flowable moisture barrier material. The flowable moisture barrier seals leaks in the dryer journal moisture barrier.

Abstract: The invention relates to a process of repairing a MCrAlY-coating of an article, which has being exposed to the hot gases of, for example, a gas turbine. The MCrAlY-coating is examined and repaired only locally where it is needed and then, subsequently, on top of the MCrAlY-coating the article is aluminized and/or chromized, avoiding the stripping of the whole coating and re-coating over the entire surface of the article. This is for replenishing the coating of Al and/or Cr that become depleted during engine operation, in an easy, cost and time saving manner.

Abstract: Castings for gas turbine parts exposed on one side to a high-temperature fluid medium have cast-in bumps on an opposite cooling surface side to enhance heat transfer. Areas on the cooling surface having defectively cast bumps, i.e., missing or partially formed bumps during casting, are thermally sprayed to provide a metallic cooling enhancement surface layer to salvage the part.

Abstract: The present invention provides a method for coating bare, untreated metal substrates wherein a coating composition comprising one or more particularly defined additives is applied directly to a bare metal substrate which has not been chemically and/or mechanically altered. The invention provides a method of coating a bare untreated metal substrate. The method requires the steps of (i) providing a bare, untreated metal substrate, the substrate being free of mechanical and/or chemical alterations, (ii) applying a two-component urethane coating composition directly to the bare, untreated metal substrate so as to make a coated metal substrate, and (iii) sanding at least a portion of the coated metal substrate within one hour from the time the two-component urethane coating composition was applied to the bare, untreated metal substrate. The resulting coated metal substrate has an initial adhesion loss of less than 20% as measured by a cross hatch adhesion test per ASTM D-3359 93.

Abstract: Process for producing a multi-layer lacquer finish, in which a surfacer coating compound is applied to a substrate optionally pre-coated with a priming layer and/or further coating layers, and a top coating comprising a color-imparting and/or special-effect-imparting base lacquer layer and a transparent clear lacquer layer, or a top coating comprising a pigmented one-layer top lacquer, is then applied, in which the surfacer coating compound which is used is one which either contains binders which are curable exclusively by free radical and/or cationic polymerization, wherein the said binders are cured by means of high-energy radiation, or is one which contains binders which are curable by free radical and/or cationic polymerization, wherein the said binders are cured by means of high-energy radiation, and additionally contains chemically cross-linking binders.

Abstract: An apparatus for identifying and clearing blockages in cooling orifices of an airfoil is described. The apparatus includes a processor for controlling the various functions of the apparatus. Light is directed into a cavity of the airfoil and a detector is used for detecting light passing through the orifices. The processor determines blockages of the orifices by comparing detected light pattern with a predetermined pattern. The apparatus further includes a nozzle controlled by the processor for directing pressurized water to open the blocked orifices.

Abstract: A method of restoring a damaged surface of a substrate to a functional condition through a filler material consisting essentially of tungsten disulfide and epoxy resin having a 10:1 ratio by weight. The filler material is cured after being applied to the damaged surface by uniformly raising the temperature to a cure temperature of the epoxy to allow any volatiles to evaporate without the creation of voids in the surface such that the resulting porosity prevents corrosion of the substrate when exposed to aromatic fuels at temperatures of 350 degrees F. The filler material consists of tungsten disulfide and a two part epoxy such as Hysol EA 9394/C-2.

Abstract: A method is provided for repairing a surface portion of an article including a metallic environmental resistant coating on a substrate. The coating includes a coating outer portion bonded with the substrate through a diffusion zone that includes at least one feature, for example Al and/or an intermetallic phase, in an amount detrimental to application of a metallic replacement coating and/or repair of the article. The method comprises removing the coating outer portion to expose a surface of the diffusion zone. The substrate and the diffusion zone are heated at a temperature and for a time sufficient to diffuse and/or dissolve at least a portion of the at least one feature in the exposed surface and in a portion of the diffusion zone beneath the exposed surface to a level below the detrimental amount. This provides a replacement surface portion integral with diffusion zone. Then a metallic replacement coating outer portion is applied to the replacement surface portion.

Abstract: A silane coating (32) is provided which affords non-stick properties to a metal surface (20, 22) of a cooking utensil (10) and which can be provided with colorant (42) to impart a stable color appearance, including white, to the utensil (10). An easy repair method is also described.

Abstract: A process for the multi-layer repair coating of substrates, wherein a base coat layer of a water-based base coat coating composition is applied to a precoated substrate and a clear coat layer of a transparent clear coat coating composition is applied to the base coat layer thus obtained, characterised in that the base coat layer of the colour- and/or special effect-imparting water-based base coat coating composition is applied in three successive spray passes, and each spray pass is executed such that uniform, adjacent and substantially non-overlapping coating strips are applied to the substrate surface to be coated.

Abstract: A method for forming a metal-containing layer on a substrate is disclosed. A slurry of the metal is first deposited on the substrate; followed by heating to remove volatile material from the slurry, and to form a layer of the metal. In another embodiment, a slurry of aluminum is deposited over the slurry of the metal, before or after the metal has been heat-treated to some degree. A diffusion heat treatment results in a coating which includes the noble-metal aluminide compound. Related articles are also disclosed.

Abstract: A method for use in two-components electrostatic image developers is disclosed, in which secure separation of a carrier coating resinous materials from a core magnetic material is achieved without affecting the properties of the core materials through process steps benign to the environment in super- or sub-critical water compositions under the conditions of a temperature of 300° C. or more and a pressure of 20 MPa. The core magnetic material is subsequently recycled for forming carrier. This method may also be useful for processing waste including magnetic materials with silicone resin coating.

Abstract: A method is provided for refurbishing a service operated metallic coating on a substrate alloy, the coating including at least within a coating outer surface at least one oxide chemically grown from at least one coating element, for example Al, and chemically bonded with the coating outer surface as a result of thermal exposure during service operation. Growth of the oxide has depleted at least a portion of the coating element from the coating. The method comprises removing the oxide from the coating outer surface while substantially retaining the metallic coating, thereby exposing in the coating outer surface at least one surface void that had been occupied by the oxide. The retained metallic coating is mechanically worked, substantially without removal of the retained coating, to close the void, providing a treated metallic coating surface over which a refurbishing coating is applied.

Abstract: A method is provided for refurbishing a service operated metallic coating on a substrate alloy, the coating including at least within a coating outer surface at least one oxide chemically grown from at least one coating element, for example Al, and chemically bonded with the coating outer surface as a result of thermal exposure during service operation. Growth of the oxide has depleted at least a portion of the coating element from the coating. The method comprises removing the oxide from the coating outer surface while substantially retaining the metallic coating, thereby exposing in the coating outer surface at least one surface void that had been occupied by the oxide. The retained metallic coating is mechanically worked, substantially without removal of the retained coating, to close the void, providing a treated metallic coating surface over which a refurbishing coating is applied.

Abstract: The present invention relates to a single-packaged epoxy resin coating composition comprising: (A) an epoxy resin having at least one epoxy group in a molecule and capable of being dissolved in the following organic solvent (D), (B) a ketimines compound having at least two primary amino groups blocked with a carbonyl compound and having no other amino groups than the above blocked amino groups, (C) a dehydrating agent and (D) an organic solvent, wherein the above organic solvent (D) comprises a hydrocarbon base solvent selected from the group consisting of an aliphatic hydrocarbon base solvent and an aromatic hydrocarbon base solvent having a boiling point of 148° C. or higher in a proportion of at least 95% by weight based on the above organic solvent (D).

Abstract: The present invention provides a repair coating process, the repair coating process consisting of grinding the part of an intermediate coating surface to be repaired and then performing a repair coating of the ground part with a thermo-curable organic solvent type repair paint (F) containing a neutralized product of a hydroxyl group-containing resin having an acid value of 5-100 mgKOH/g and a crosslinking agent in forming multilayer coating films by coating an electro-deposition paint (A) and an intermediate paint (B) and curing them by heating, then, after performing a repair coating on the intermediate coating surface, successively coating wet-on-wet a white water base coat (C), a pearly base coat (D), and a clear coat (E), and then curing by crosslinking the films of the above-mentioned coats (C), (D), and (E) simultaneously through heating.

Abstract: Castings for gas turbine parts exposed on one side to a high-temperature fluid medium have cast-in bumps on an opposite cooling surface side to enhance heat transfer. Areas on the cooling surface having defectively cast bumps, i.e., missing or partially formed bumps during casting, are coated with a braze alloy and cooling enhancement material to salvage the part.

Abstract: A primary layer of an MCrAlY-type material is first applied to a metal-based substrate by a vacuum plasma spray (VPS) technique, or by HVOF. A secondary layer is then also applied by VPS or HVOF. It is formed of the following alloy (in atom percent): 0 to about 25 cobalt; about 7 to 25 chromium; about 18 to about 55 aluminum; 0 to about 1 yttrium; and 0 to about 2 silicon, with the balance comprising nickel. The applied layers are then heat-treated. Related articles are also described.

Abstract: A method for applying a protective coating to a surface. The method is achieved by applying a radiation curable reactive coating material to the surface and exposing the applied coating to a source of light for a predetermined time and at a predetermined intensity to effect polymerization of the coating.

Abstract: A zinc coating directly covers a bare ferrous base of parking meter housing parts. A non-epoxy thermosetting electrically insulating organic non-epoxy powder coating directly covers the zinc coating. The organic coating is directly applied to the zinc coating by electrostatically charging the powder and parts with opposite d.c. voltage polarities and by heating the powder so it adheres to and covers the zinc coating. Alternatively, the base is zinc, directly covered by the organic powder coating.

Abstract: The present invention relates to a method of introducing enhanced biofouling release properties to intact biofouling release coatings by exposing the surface of the biofouling release coating to a restorative compound for a time sufficient to effect enhancement of biofouling release properties. Also disclosed are kits useful in carrying out these processes.

Abstract: A method of repairing a thermal barrier coating on a component designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method more particularly involves repairing a thermal barrier coating on a component that has suffered localized spallation of the thermal barrier coating. After cleaning the surface area of the component exposed by the localized spallation, a ceramic paste comprising a ceramic powder in a binder is applied to the surface area of the component. The binder is then reacted to yield a ceramic-containing repair coating that covers the surface area of the component and comprises the ceramic powder in a matrix of a material formed when the binder was reacted. The binder is preferably a ceramic precursor material that can be converted immediately to a ceramic or allowed to thermally decompose over time to form a ceramic, such that the repair coating has a ceramic matrix.

Abstract: Electroless deposition of Cu provides for repair of copper seed layers formed by vacuum deposition processes, for formation of copper seed layers on catalytic materials, and for bulk fill of damascene trenches and via openings. Electroless plating baths for such depositions are formulated for both room temperature and elevated temperature operation, and each include a copper source, an environmentally friendly reducing agent, a pH buffer, a complexing agent, and a surfactant.

Abstract: A method for improving the cooling effectiveness of a gaseous coolant stream which flows through at least one passage hole in a substrate to an exit site on a high-temperature surface of the substrate is disclosed. The method comprises disrupting the coolant stream at the exit site, so that the coolant stream contacts a greater area of the high-temperature surface. In some embodiments, the exit site is a crater. Moreover, the exit site may be formed within a coating applied over the substrate, e.g., a thermal barrier coating applied over a superalloy substrate. Related articles are also disclosed.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: This invention pertains to the repair of parts comprising metals, and surfaces and coatings of these parts using reactive metals coating processes. Processes such as chemical vapor deposition (CVD), physical vapor deposition (PVD), plasma spray, and reactive coating (boronizing, carburizing, nitridizing, carbonitridizing, etc.) are known for producing durable coatings or surfaces on metal parts, and the present invention provides a means to spot-repair these coatings or surfaces without excessive buildup of repair material on undamaged areas.

Abstract: A ceramic welding process for the formation of a coherent refractory repair mass on a surface of an electrocast refractory material includes providing an electrocast refractory material having a surface to be repaired; providing a first powder mixture comprised of combustible particles, refractory particles, and at least one constituent which enhances production of a vitreous phase in the coherent refractory repair mass; and projecting the first powder mixture in a gas stream containing oxygen against the surface to be repaired so that the combustible particles react with the projected oxygen against the surface in a highly exothermic manner and release sufficient heat of combustion to form a first coherent refractory repair mass.

Abstract: The present invention provides a method for repair coating characterized by applying an epoxy-polyamine resin base coating composition comprising an epoxy resin having at least one epoxy resin in a molecule and an amine base curing agent as resinous components on a deteriorated coating film which is selected from a tar epoxy resin coating film, a tar urethane resin coating film, a modified epoxy resin coating film, a modified urethane resin coating film, an epoxy-polyamine resin coating film and an epoxy urethane resin coating film and which has a water content of 0.3 to 5% by weight.

Abstract: A process for the multi-layer repair coating of substrates, wherein a base coat layer of a water-based base coat coating composition is applied to a precoated substrate and a clear coat layer of a transparent clear coat coating composition is applied to the base coat layer thus obtained, characterized in that the base coat layer of the color- and/or special effect-imparting water-based base coat coating composition is applied in three successive spray passes, and each spray pass is executed such that uniform, adjacent and substantially non-overlapping coating strips are applied to the substrate surface to be coated.

Abstract: A cold spray process (20) for applying an abradable coating (16) to a substrate material (12). A bond coat layer (14) and/or an abradable coating material layer (16) are applied to a substrate (12) by directing particles of the material toward the substrate surface at a velocity sufficiently high to cause the particles to deform and to adhere to the surface. Particles of the bond coat material may first be directed toward the substrate surface at a velocity sufficiently high to clean the surface (24) but not sufficiently high to cause the particles to deform and to adhere to the surface.

Abstract: A computer controlled method utilizing robots for the fairing and painting of marine vessel surfaces comprising the steps of analyzing the vessel hull and/or superstructure for imperfections; applying a fairing compound to the imperfections; smoothing the imperfections into alignment with the hull and/or superstructure; and applying a final paint finish to the hull and/or superstructure.

Abstract: The present invention provides a coating composition capable of forming a coating film having good performances such as an adhesive property even if coated on a deteriorated coating film surface of a high rust-preventive coating film of a tar epoxy resin coating material and the like without providing pre-treatment, and a coating method thereof. The above coating composition is a coating composition of an organic solvent type or solventless type comprising an epoxy resin having at least one epoxy group in a molecule and an amine base curing agent as resin components, wherein moisture of 1 to 30 parts by weight per 100 parts by weight of the solid matter of the coating composition is contained.

Abstract: A process for remanufacturing a charging member having at least two layers on a conductive support is described. The process involves carrying out mechanical abrasion to remove at least a surface layer of the charging member, followed by forming a layer thereon. Also, a charging member remanufactured by the process and a process cartridge having the hanging member are described.

Abstract: A method is disclosed for preventing harm caused by constrictions in the cooling holes of gas-cooled parts, in particular of gas turbines and/or burners. These constrictions form because the walls of the gas-cooled parts through which the cooling holes extend and which are covered on their outside with a protective, first coating are provided during the course of an overhaul with a second, repeat coating, and coating material is deposited in the cooling holes. Constant flow ratios in the cooling holes are achieved in a simple manner in that prior to the overhaul, the cooling holes are constricted with first means to an extent that corresponds to the later constrictions created during the course of the second coating. The first means are removed after the overhaul. The first means takes the form of an insert with holes that constrict the flow through the cooling holes.

Abstract: The invention relates to a process of repairing a MCrAlY-coating of an article, which has being exposed to the hot gases of, for example, a gas turbine. The MCrAlY-coating is examined and repaired only locally where it is needed and then, subsequently, on top of the MCrAlY-coating the article is aluminized and/or chromized, avoiding the stripping of the whole coating and re-coating over the entire surface of the article. This is for replenishing the coating of Al and/or Cr that become depleted during engine operation, in an easy, cost and time saving manner.