Abstract: A method for making a thin-film electrode, either an anode or a cathode, by preparing a precursor solution using an alkoxide reactant, depositing multiple thin film layers with each layer approximately 500–1000 ? in thickness, and heating the layers to above 600° C. to achieve a material with electrochemical properties suitable for use in a thin film battery. The preparation of the anode precursor solution uses Sn(OCH2C(CH3)3)2 dissolved in a solvent in the presence of HO2CCH3 and the cathode precursor solution is formed by dissolving a mixture of (Li(OCH2C(CH3)3))8 and Co(O2CCH3).H2O in at least one polar solvent.

Abstract: Disclosed is a process to rapidly spin-apply an AR coating system to a backside of a prescription lens. The AR coating system comprises a polyurethane primer layer, a siloxane thermally cured scratch resistant coating layer, a two-layer sol-gel AR coating, and a hydrophobic layer. The process comprising steps of spin-applying each of the layers provides a quick way to furnish a prescription lens that is AR coated on both sides.

Abstract: The invention relates to thermally tempered safety glass comprising an non-abrasive and porous SiO2 layer which is stable during sintering and has a refractive index of between 1.25 and 1.40. The inventive safety glass can be obtained by coating standard soda-lime glass with an aqueous coating solution having a pH value of between 3 and 8 and containing between 0.5 and 5.0 wt. % of [SiOx(OH)y]n particles (0<y<4 and 0<x<2) having a particle size of between 10 and 60 nm, and a surfactant mixture. The coated glass is then dried, thermally hardened at temperatures of at least 600° C. for several minutes, and thermally tempered by a flow of air.

Abstract: A method for applying a coating system that is applied to a surface of a component for preventing or at least substantially preventing interdiffusion between the component surface and a protective thermal layer applied to the component surface when the thermal layer is exposed to elevated temperatures. The method includes applying a carrier layer containing aluminum to the component surface. Next, the layer is heated to a first predetermined temperature for a first predetermined period of time in the substantial absence of oxygen to bond the aluminum with the component surface, the heat dissolving the carrier portion of the aluminum layer. The remaining portion of the aluminum layer is then heated to a second predetermined temperature for a second predetermined period of time to form an oxidized aluminum layer. Finally, at least one protective thermal layer is applied over the oxidized aluminum layer.

Abstract: A nickel-base superalloy substrate includes a surface region having an integrated aluminum content of from about 18 to about 24 percent by weight and an integrated platinum content of from about 18 to about 45 percent by weight, with the balance components of the substrate. The substrate is preferably a single-crystal advanced superalloy selected for use at high temperatures. The substrate may optionally have a ceramic layer deposited over the platinum-aluminide region, to produce a thermal barrier coating system. The platinum-aluminide region is produced by diffusing platinum into the substrate surface, and thereafter diffusing aluminum into the substrate surface.

Abstract: An article having an internal passage therein and an internal article surface is coated by providing a coating slurry that is a mixture of a deposition source including a source of aluminum, a halide activator, and a flowable carrier comprising a flowable compound selected from the group consisting of a flowable organic compound and a flowable inorganic compound. There is no oxide dispersant in the coating slurry. The coating slurry is introduced into the internal passage and dried to remove at least a portion of the carrier therefrom and leave a dried coating material. The article surface in gaseous communication with the dried coating material is heated to form an aluminum-containing coating bonded to the article surface. Any residual dried coating material is removed by blowing compressed air through the internal passage.

Abstract: A method for applying a bond coat on a metal-based substrate is described. A slurry which contains braze material and a volatile component is deposited on the substrate. The slurry can also include bond coat material. Alternatively, the bond coat material can be applied afterward, in solid form or in the form of a second slurry. The slurry and bond coat are then dried and fused to the substrate. A repair technique using this slurry is also described, along with related compositions and articles.

Abstract: A method of manufacturing a semiconductor device has the steps of: (a) evacuating a sputtering chamber to a pressure of 1.5×10?8 torr to 9×10?8 torr and heating a silicon substrate to a temperature of 330° C. to 395° C.; (b) sputtering Co on the heated silicon substrate; (c) after the step (b), forming a cap layer having a small oxygen transmission performance on the silicon substrate without exposing the silicon substrate in air; (d) after the step (c), performing primary annealing; (e) after the step (d), removing the cap layer and unreacted Co; and (f) after the step (e), performing secondary annealing by heating the silicon substrate to a temperature of 450° C. to 750° C.

Abstract: A method of manufacturing a ceramic includes forming a film which includes a complex oxide material having an oxygen octahedral structure and a paraelectric material having a catalytic effect for the complex oxide material in a mixed state, and performing a heat treatment to the film, wherein the paraelectric material is one of a layered catalytic substance which includes Si in the constituent elements and a layered catalytic substance which includes Si and Ge in the constituent elements. The heat treatment includes sintering and post-annealing. At least the post-annealing is performed in a pressurized atmosphere including at least one of oxygen and ozone. A ceramic is a complex oxide having an oxygen octahedral structure, and has Si and Ge in the oxygen octahedral structure.

Abstract: A process for producing a rigid reticulated article involves coating a reticulated substrate which has open, interconnected porosity with a first dispersion comprising a ceramic or metal powder to form a first coating thereon; drying the coated reticulated substrate; contacting the coated reticulated substrate with one or more additional dispersions in succession to form one or more additional coatings thereon; drying the additional coatings between the steps of contacting; heating the coated reticulated substrate to pyrolyze organic components; and sintering the coated reticulated substrate to form a reticulated article, wherein each dispersion has a viscosity less than that of all preceding dispersions. A rigid reticulated article includes inner, intermediate and outer sintered layers of material in which the inner and outer layers are of different composition and the intermediate layer is a composite of the inner and outer layers.

Abstract: A new method for repairing turbine engine components is provided. The method utilizes a cold gas-dynamic spray technique to repair degradation on turbine blades, vanes and other components. In the cold gas-dynamic spray process particles at a temperature below their fusing temperature are accelerated and directed to a target surface on the turbine blade. When the particles strike the target surface, the kinetic energy of the particles is converted into plastic deformation of the particle, causing the particle to form a strong bond with the target surface. Post-spray processing is then performed to consolidate and homogenize the applied materials and restore integrity to the material properties in the repaired turbine component. Thus, the cold gas-dynamic spray process and post-spray processing can be employed to effectively repair degraded areas on gas turbine components.

Abstract: A low cost aluminide process for moderate temperature applications. A gas turbine engine component is cleaned and coated with a layer of metal, generally aluminum, containing paint. The metal containing paint layer is heated to a first temperature for a first period of time in an air environment to volatilize the solvents in the paint. The metal containing paint layer is heated to a second temperature for a second period of time in an oxygen-free atmosphere to volatilize the solvents in the paint. The now metal layer and component are heated to a third temperature for a third period of time to interdiffuse the metal and the metal of the component. The component and diffusion layer are then cooled to ambient temperature.

Abstract: A method for applying a coating system that is applied to a surface of a component, such as a turbine nozzle, for preventing or at least substantially preventing interdiffusion between the component surface and a protective thermal layer applied to the component surface when the thermal layer is exposed to elevated temperatures. The method includes applying a carrier layer containing aluminum to the component surface. Next, the layer is heated to a first predetermined temperature for a first predetermined period of time in the substantial absence of oxygen to bond the aluminum with the component surface, the heat dissolving the carrier portion of the aluminum layer. The remaining portion of the aluminum layer is then heated to a second predetermined temperature for a second predetermined period of time to form an oxidized aluminum layer. Finally, at least one protective thermal layer is applied over the oxidized aluminum layer.

Abstract: A method for applying a coating system that is applied to a surface of a component for preventing or at least substantially preventing interdiffusion between the component surface and a protective thermal layer applied to the component surface when the thermal layer is exposed to elevated temperatures. The method includes applying a carrier layer containing aluminum to the component surface. Next, the layer is heated to a first predetermined temperature for a first predetermined period of time in the substantial absence of oxygen to bond the aluminum with the component surface, the heat dissolving the carrier portion of the aluminum layer. The remaining portion of the aluminum layer is then heated to a second predetermined temperature for a second predetermined period of time to form an oxidized aluminum layer. Finally, at least one protective thermal layer is applied over the oxidized aluminum layer.

Abstract: A low cost chromide and chromide/aluminide process for moderate temperature applications. A gas turbine engine component is cleaned and coated with a layer of metal, generally chromium or chromium and aluminum, containing paint. The metal containing paint layer is heated to a first temperature for a first period of time in an air environment to volatilize the solvents in the paint. The metal containing paint layer is heated to a second temperature for a second period of time in an oxygen-free atmosphere to volatilize the solvents in the paint. The now metal layer and component are heated to a third temperature for a third period of time to interdiffuse the metal and the metal of the component. The component and diffusion layer are then cooled to ambient temperature.

Abstract: An in-situ method for repairing a thermal barrier coating deposited on a component that has suffered localized spallation including depositing a ceramic paste on a surface area of the component exposed by the localized spallation, the ceramic paste including a ceramic material in a binder material, the ceramic material including solid zirconia particles, the binder material including a silicone compound. The method also including heating the binder material to yield a repair coating that covers the surface area of the component, the silicone compound promoting the bonding of the solid zirconia particles.

Abstract: The invention is directed to a photoresist-free method for depositing films composed of metals, such as copper or silica, or their oxides from metal complexes. More specifically, the method involves applying an amorphous film of a metal complex to a substrate. The metal complexes have a metal and a photo-degradable ligand. A preferred ligand is acac or alkyl-acac, expecially in combination with acetate ligands. These films, upon, for example, thermal, photochemical or electron beam irradiation may be converted to the metal or its oxides. By using either directed light or electron beams, this may lead to a patterned metal or metal oxide film in a single step. Low temperature baking may be used to remove residual organics from the deposited film. If silica is the metal, the deposited film has excellent smoothness and dielectric properties.

Abstract: A system for producing Erbium Oxide thin films with increased photoluminescence. The system includes a depositing stage for forming Erbium Oxide molecules by reacting Erbium sputtered atoms with O2 in a gas phase and creating the Erbium Oxide thin film by depositing the Erbium Oxide molecules on a substrate coated with Silicon Oxide. The system further includes an annealing stage for annealing the Erbium Oxide thin films by utilizing a low temperature treatment for a specified amount of time and temperature followed by a high temperature treatment for another specified amount of time and temperature, wherein the crystallinity of the thin films has improved.

Abstract: A single-step heat treating and surface coating process is provided for steel self-piercing rivets for joining 5xxx and 6xxx aluminum panels. In this process, two coats of zinc and aluminum flakes in an inorganic binder are applied to the steel rivets. After each coating, the rivets are heated to set and cure the coats and to achieve the desired microstructure and hardness level for joining 5xxx and 6xxx aluminum panels. The coating curing step combines the heat treatment with surface coating into a single-step procedure.

Abstract: A calibrating consists at least in part of a carbon fiber composite body. The composite body is formed from a porous material from a carbon-containing matrix, into which carbon fibers are embedded, this matrix is thickened by fluid infiltration of Si, which is essentially converted by reaction with carbon to SiC. The overall portion of Si and SIC is a maximum of 60% by volume. The carbon fibers have a minimum length of 3 mm.

Abstract: A method of forming a perovskite thin film includes preparing a perovskite precursor solution; preparing a silicon substrate for deposition of a perovskite thin film, including forming a bottom electrode on the substrate; securing the substrate in a spin-coating apparatus and spinning the substrate at a predetermined spin rate; injecting a perovskite precursor solution into the spin-coating apparatus thereby coating the substrate with the perovskite precursor solution to form a coated substrate; baking the coated substrate at temperatures which increase incrementally from about 90° C. to 300° C.; and annealing the coated substrate at a temperature of between about 500° C. to 800° C. for between five minutes to fifteen minutes.

Abstract: A process of coating a refractory turbine part with a protective coating which is ultimately diffusion bonded to the part. A slurry coating material is prepared from a mixture of a silicon alkyd paint and suspended particles of an aluminum or aluminum alloy powder. Parts may be dipped in the slurry and subsequently be heat treated in selected atmospheres and temperatures to diffuse the coating into the surface of the part.

Abstract: A process for making an alkaline resistant material comprises the steps of grinding together 0-40% light magnesia, 0-80% roasted magnesia, 10-54% ceramic clay, 0-9% limestone, 1-4% water glass, 0-1.5% carboxymethyl cellusolve, 0-27% talc, 0-3% calcium or barium carbonate to a particle size of less than 50 microns, mixing the ground mixture with water to produce a paste containing <23% wt. water, shaping the paste to a desired shape, drying the shaped product at a temperature of 110 degrees Centigrade, and firing the dried shaped product in a kiln at 1350 degrees Centigrade. The resulting alkali resistant ceramic contains 25-76 wt % MgO, 13-47% SiO2, 5-20 wt % Al2O3, and 1-10 wt % Fe2O3, CaO, K2O, and/or Na2O, with forsterite and spinel being the dominant crystalline phases.

Abstract: The present invention is a method of forming thick films of crystalline YBa2Cu3O7 that includes forming a precursor film comprising barium fluoride (BaF2), yttrium (Y) and copper (Cu). The precursor film is heat-treated at a temperature above 500° C. in the presence of oxygen, nitrogen and water vapor at sub-atmospheric pressure to form a crystalline structure. The crystalline structure is then annealed at about 500° C. in the presence of oxygen to form the crystalline YBa2Cu3O7 film. The YBa2Cu3O7 film formed by this method has a resistivity of from about 100 to about 600 &mgr;Ohm-cm at room temperature and a critical current density measured at 77 K in a magnetic field of 1 Tesla of about 1.0×105 Ampere per square centimeter (0.1 MA/cm2) or greater.

Abstract: A low cost chromide and chromide/aluminide process for moderate temperature applications. A gas turbine engine component is cleaned and coated with a layer of metal, generally chromium or chromium and aluminum, containing paint. The metal containing paint layer is heated to a first temperature for a first period of time in an air environment to volatilize the solvents in the paint. The metal containing paint layer is heated to a second temperature for a second period of time in an oxygen-free atmosphere to volatilize the solvents in the paint. The now metal layer and component are heated to a third temperature for a third period of time to interdiffuse the metal and the metal of the component. The component and diffusion layer are then cooled to ambient temperature.

Abstract: Provided is a method to produce high-temperature lubricious glassy films on silicon-based ceramics. The method comprises the steps of (a) oxidizing a silicon-based component, (b) coating the oxidized component with an alkali metal compound, and (c) heating the component to a high temperature in a sulfur-rich oxidizing environment. The steady state sliding friction coefficient values obtained with this system in 600° C. air are similar to those obtained with liquid lubricants operating under boundary lubrication conditions at much lower temperatures.

Abstract: A mercury-containing material, a method for producing the same and a fluorescent lamp using the same that can enclose a minimal amount of mercury in a glass bulb precisely, prevent flaws in a fluorescent coating while suppressing a noise during a lamp transportation, and prevent deterioration in appearance are provided. A surface of liquid mercury is coated with a continuous film made of metal oxide or metal complex oxide by dipping the mercury in a metal alkoxide solution and then heating the mercury on which the metal alkoxide solution adheres. Accordingly, the minimal amount of the mercury can be enclosed in the fluorescent lamp precisely, thus achieving friendliness to the environment. It also is possible to prevent flaws in the fluorescent coating while suppressing a noise during the lamp transportation and further to prevent deterioration in appearance.

Abstract: Silica-based low dielectric constant materials having three-dimensional network structures containing siloxane backbones which comprise SiO4 tetrahedron structural units, as well as their production and use. The materials can be applied as interlayer dielectrics for semiconductor elements and the like.

Abstract: A composition for application to a substrate to form a an electrically conductive coating thereon. The composition includes a sol-gel solution filled with a conductive powder. The coating may be conductive or resistive depending on the application. A process is provided for applying such a coating by mixing a sol-gel solution with up to about 90% by weight of the solution of a conductive powder selected from the group consisting of ceramics, inter-ceramics, semi-conductors and metals so as to provide a uniform stable dispersion. The stable dispersion is applied to a substrate and the coated substrate is fired at a temperature sufficient to remove organic constituents and to produce at least a partially conductive film on the substrate. A heating device is also provided which is a product of the above process.

Abstract: Processes for forming a filter material are provided. The processes include the steps of coating a filter particle with a lignosulfonate, carbonizing the coating, and activating the coating.

Abstract: A ceramic-coated fiberglass member and method for manufacturing the same that withstands flames or high temperatures for a substantial period of time. A fiberglass pipe is washed and dried. The pipe is sanded axially along the lengthwise direction of the pipe to expose pores on the pipes. A first ceramic base coating is applied evenly on the pipe. Then, the first ceramic base coating is burnished into the pores. Next, the first ceramic base coating is dried so that substantially no moisture is left in the first ceramic base coating. The first ceramic base coating is axially burnished along the lengthwise direction of the pipe. Then, a second ceramic base coating is applied on the first ceramic base coating. The pipe is dried with first and second ceramic base coatings thereon. The pipe is burnished axially with first and second ceramic base coatings. Subsequently, a first ceramic top coating is applied evenly on the second ceramic base coating.

Abstract: This invention comprises methods for making nanostructured and nanoporous thin film structures of various compositions. These films can be directly patterned. In these methods, precursor films are deposited on a surface and different components of the precursor film are reacted under selected conditions, forming a nanostructured or nanoporous film. Such films can be used in a variety of applications, for example, low k dielectrics, sensors, catalysts, conductors or magnetic films. Nanostructured films can be created: (1) using one precursor component and two reactions, (2) using two or more components based on differential rates of photochemical conversion, (3) using two precursors based on the thermal sensitivity of one precursor and the photochemical sensitivity of the other, and (4) by photochemical reaction of a precursor film and selected removal of a largely unreacted component from the film.

Abstract: A corrosion-inhibiting coating, process, and system that provides a tight, adherent zinc- or zinc-alloy coating that is directly deposited onto steel or cast iron surfaces for enhanced corrosion protection. A process for applying the coating is also provided. The process includes the application of two sequential aqueous baths. The first bath contains a precursor zinc compound while the second bath contains a reducing agent to deposit the zinc directly upon the steel or cast iron.

Abstract: A process is described for formation of oxide films independent of thickness from precursor films comprising metals, metal oxides, and metal fluorides with properties and structures similar to those previously only obtained in thin films, for example less than about 0.4 microns.

Abstract: This invention has enabled a new, simple thin film nanoporous dielectric fabrication method. In general, this invention uses glycerol, or another low volatility compound, as a solvent. This new method allows thin film aerogels/low density xerogels to be made without supercritical drying, freeze drying, or a surface modification step before drying. Thus, this invention allows production of nanoporous dielectrics at room temperature and atmospheric pressure, without a separate surface modification step. Although this new method allows fabrication of aerogels without substantial pore collapse during drying, there may be some permanent shrinkage during aging and/or drying. This invention allows controlled porosity thin film nanoporous aerogels to be deposited, gelled, aged, and dried without atmospheric controls.

Abstract: A single-step heat treating and surface coating process is provided for steel self-piercing rivets for joining 5xxx and 6xxx aluminum panels. In this process, two coats of zinc and aluminum flakes in an inorganic binder are applied to the steel rivets. After each coating, the rivets are heated to set and cure the coats and to achieve the desired microstructure and hardness level for joining 5xxx and 6xxx aluminum panels. The coating curing step combines the heat treatment with surface coating into a single-step procedure.

Abstract: As a method of treating a frame of spectacles which enables fine color modulation with ease, good reproducibility, and at low cost, there is provided a method of treating the surface of a frame of spectacles characterized in that a surface treating composition comprising a metal complex is used to form a coating layer on part or the whole of the surface of the frame of spectacles.

Abstract: There is provided a ceramic coating of zirconium diboride, silicon carbide, zirconium phosphate and silicon phosphate, that protects carbon-based materials from oxidation in high temperature oxidizing environments. The coating is applied at room temperature with a brush, roller, squeegee, doctor blade, spray gun, etc., and cured at room temperature. The cured material forms a hard, protective ceramic shell. The coating can be applied to various carbon based materials including, but not limited to, amorphous carbon foam, graphitic foam, monolithic graphite, and carbon-carbon composites. Alternative compositions of the coating can be the partial or complete substitution of hafnium diboride for zirconium diboride. Additional modifications of the coating can be accomplished by partial substitution of the borides or silicides of Ti, Ta, Cr, Nb, Ti, V, Re, for zirconium diboride.

Abstract: A first thin film including at least one transition metal selected from the group consisting of Co, Fe and Ni, and a second thin film including at least one platinum group element selected from the group consisting of Pt and Pd are prepared. Then, a multilayered structure where said first thin film and said second thin film are stacked is formed. Then, the multilayered structure is heated at the same time or after the formation of said multilayered structure, thereby to counter-diffuse constituent elements of said first thin film and said second thin film and alloy said at least one transition metal and said platinum group element.

Abstract: A substrate is protected by a multilayer protective coating having an oxide layer, and a phosphate/organic binder layer initially overlying the oxide layer. The multilayer protective coating is cured by first degassing the multilayer protective coating in a pre-cure degassing temperature range of from about 250° F. to about 500° F. for a time of at least about 30 minutes. The multilayer protective coating is thereafter heated to a curing temperature range of from about 1200° F. to about 1400° F. for a time of at least about 30 minutes.

Abstract: In a method for manufacturing an Al clad product, first, cladding material is fused and coated on base material having Al. Then, slurry material is coated on the cladding material coated on the base material, the slurry material including mixture of a flux powder, a resin binder powder and a diluent. Thereafter, the slurry material is hardened to thereby provide a hardened product including the base material, the cladding material and hardened slurry material. In a subsequent step, the hardened product is brazed to thereby provide an Al clad product, wherein the diluent included in the slurry material is gasified in the hardening process of the slurry material and the cladding material is fused by employing an arc discharge technique.

Abstract: A process for producing a coating on a refractory structural member, in which a noble metal alloy is applied as a coating material to the refractory structural member. The noble metal alloy contains, among other constituents, an oxidizable substance, which includes boron and/or phosphorus and/or antimony and/or arsenic. The refractory structural member and the coating are heated at least once in an oxygen-containing atmosphere to a temperature T that is greater than or equal to the liquidus temperature TL of the noble metal alloy. The oxidizable substance is oxidized during this heating process, and the oxide that has formed is at least partially vaporized. The temperature T is maintained until the proportion of oxidizable substance in the coating is <0.1 atomic percent, and the coated refractory structural member is then cooled.

Abstract: Magnetic recording media exhibiting high SNR and high thermal stability are produced by sputter depositing a magnetic alloy overlying a non-magnetic substrate, e.g., on an underlayer, heating to eliminate thermally unstable small grains thereby increasing the average grain size of the magnetic alloy layer but narrowing the grain size distribution, depositing a layer comprising a non-ferromagnetic element, and then heating to diffuse the non-ferromagnetic element into the grain boundaries of the heat treated magnetic alloy layer. Embodiments include sputter depositing a magnetic alloy layer comprising Co and Pt on an underlayer, heating at a temperature of about 150° C. to about 600° C. to increase the average grain size to about 8 to about 10 nm, depositing a layer comprising Cr, Mn or Ta, at a thickness up to about 25 Å, e.g., up to about 10 Å, on the magnetic alloy layer and heating to diffuse the Cr, Mn or Ta into the grain boundaries of the magnetic alloy layer.

Abstract: Processes for the preparation of adherent polyvinylidene fluoride, hexafluoropropylene coatings on objects and for the direct production of open celled foams from a polymer latex without a need for any blowing agent.

Abstract: A method for producing the piezoelectric thin film is based on a sol-gel process and comprises the steps of: coating a substrate with a sol composition comprising a sol, of a metal component for constituting a piezoelectric film, and a polymer compound and then drying the coating to form a film; pre-sintering the film to form a porous thin film of gel comprising an amorphous metal oxide; pre-annealing the porous thin film of gel to convert the film to a film of a crystalline metal oxide; repeating the steps at least once to form laminated films of a crystalline metal oxide; and annealing the films thus prepared to grow crystal grains of perovskite type in the film into a larger size.

Abstract: The invention relates to a method for applying a non-permeable, ceramic layer of a thickness of not more than about 100 &mgr;m to a ceramic or metallic body by applying a solution of one or more elastomers, which elastomers contain substantially not exclusively sulfur, carbon, hydrogen and oxygen, optionally drying, and pyrolyzing to form a porous layer and subsequently sintering at increased temperature to form a non-permeable ceramic layer.

Abstract: A process is provided for the preparation of a metallic oxide composite including mixing an aqueous solution of a water-soluble metal compound and colloidal silica, depositing the mixture upon a substrate, heating the mixture-coated substrates at temperatures from about 150° C. to about 300° C. for time sufficient to form a metallic oxide film, and, removing the silica from the metallic oxide film whereby a porous metal oxide structure is formed.

Abstract: An internal passage of an article such as a gas turbine airfoil is coated with an aluminum-containing coating. To accomplish this coating process, a coating slurry of a mixture of a carrier component of water and a hectorite clay or a bentonite clay, together with a solids component of a source of aluminum, a halide activator, and an oxide dispersant, is prepared. The coating slurry is applied to the internal passage of the gas turbine airfoil and dried. The gas turbine airfoil and the applied coating slurry are heated to form an aluminum-containing coating bonded to the internal passage of the gas turbine airfoil. Excess coating material is removed from the article internal passage.

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: An article is fabricated with a ceramic surface having a controllable surface finish. In one form, the ceramic is applied as a coating to a substrate article. Preferably, an aqueous coating mixture of phosphoric acid, alumina powder, and cordierite powder is prepared. The mixture is contacted to the surface of the article, and a mechanical overpressure is applied to the external surface of the mixture using a pressing tool. The surface character of the pressing tool, such as a smooth surface or an intentionally patterned surface, is reproduced on the surface of the final ceramic coating. The coating is heated to a moderate temperature to set the ceramic of the coating, and thereafter the coating Is heated to a higher, but still intermediate temperature, to cure the coating.