Abstract: Disclosed is a process for making a composite material that contains structured particles. The process includes providing a first precursor in the form of a dry precursor powder, a precursor liquid, a precursor vapor of a liquid and/or a precursor gas. The process also includes providing a plasma that has a high field zone and passing the first precursor through the high field zone of the plasma. As the first precursor passes through the high field zone of the plasma, at least part of the first precursor is decomposed. An aerosol having a second precursor is provided downstream of the high field zone of the plasma and the decomposed first material is allowed to condense onto the second precursor to from structured particles.

Abstract: A plasma coating system includes at least one coating station with a first side and a second side defining a pathway with at least one bend. The coating station also includes a first plasma arc that provides a plasma jet directed towards a substrate. The first plasma arc is positioned on either the first side or the second side of the bend.

Abstract: The invention relates to a plasma coating device (10) and a method for homogenous coating of a substrate (12). It comprises a particle reservoir (14), a dosing device (16) for dosing the particles (15) contained in the particle reservoir (14), a processing chamber (20) and a transport line (18) to convey particles (15) into the processing chamber (20). The processing chamber pressure (P1) in the processing chamber (20) is lower than the particle reservoir pressure (P2) in the particle reservoir (14).

Abstract: A system or method for applying a protective environmental coating for a gas turbine component. The coating includes a bond layer applied to a substrate comprised of a ceramic matrix composite material and environmental barrier coating layers. The first environmental barrier coating layer is bonded to the substrate by the bond layer. The bond layer comprises silicon and particles consisting of particles of Lanthanum or Cerium.

Abstract: A method for preparing a protective coating against oxidation on at least one surface of at least one part made of at least one material capable of being oxidized, wherein the following successive steps are carried out: a) each of the particles of a powder made of a first ceramic selected from refractory ceramics and ceramics which resist oxidation, is coated with at least one layer selected from layers made of a refractory ceramic, layers made of a ceramic which resist oxidation, and layers made of a refractory metal, provided that the coating comprises at least one ceramic which resists oxidation, and at least one refractory ceramic or metal; b) the powder is deposited onto the surface to be coated of the part; c) sintering of the powder is achieved on the surface of the part by a Spark Plasma Sintering (SPS) Method; d) the part is cooled; e) the cooled part, coated on at least one of its surfaces with a protective refractory monolayer coating against oxidation, with a three-dimensional microstructure, i

Abstract: A method of processing a ceramic electrolyte suitable for use in a fuel cell is provided. The method comprises situating a ceramic electrolyte layer over an anode layer; and subjecting the ceramic electrolyte layer to a stress prior to operation of the fuel cell, by: exposing the top surface of the electrolyte layer to an oxidizing atmosphere and the bottom surface of the electrolyte layer to a reducing atmosphere; and heating the electrolyte layer. The stress causes a substantial increase in the number of microcracks, or in the average size of the microcracks, or in both the number of the microcracks and their average size. A solid oxide fuel cell comprising a ceramic electrolyte layer processed by the disclosed method is also provided.

Abstract: A thermal spraying method includes forming a coating layer of heat resistant resin on the whole spray area of the metal surface, securely fixing a test piece of the same material as that of the metal as a constituent of heat resistant equipment on the surface of the coating layer, spraying a heat shield coating material onto the test piece, detaching the test piece from the surface of the coating layer, inspecting the condition of spray and setting spray conditions, removing the coating layer and, under the above set spray conditions, spraying the heat shield coating material onto the metal surface to thereby form a heat shield coating layer.

Abstract: A cylinder liner for an internal combustion engine includes a liner body defining a longitudinal axis coated with a coating on the interior surface of the liner body that varies in thickness along the longitudinal axis. The coating on the interior surface is thicker in a region of the interior surface corresponding to a top dead center or a bottom dead center of a piston.

Abstract: Disclosed is a process for producing a run-in coating (20, 24, 32, 44) on a component of a turbomachine, in particular of a gas turbine. The run-in coating is applied and produced on the component of the turbomachine by a kinetic cold gas compacting process (K3). The invention also encompasses a run-in coating for a static or rotating component of a turbomachine and a static or rotating component of a turbomachine, in particular of a gas turbine, having at least one run-in coating.

Abstract: A method for the production of a brake disc from a basic body (1), which has a friction ring surface (2). The method includes the steps of the provision of the basic body (1) and the roughening of the friction ring surface (2) by directing an electron beam (5) at the friction ring surface (2). A defined quantity of recesses (3) per mm2 of the friction ring surface (2) is created in the friction ring surface (2). The arrangement of the recesses (3) with respect to one another is predetermined and each recess (3) has a predetermined depth and shape. Then a coating (4) is applied to the friction ring surface without the implementation of an chemical etching step. Furthermore, the invention discloses a corresponding brake disc.

Abstract: According to one embodiment, an insulation film is formed over the surface, backside, and sides of a first substrate. Next, the insulation film formed over the surface of the first substrate is removed. Then, a joining layer is formed over the surface of the first substrate, from which the insulation film has been removed. Subsequently, the first substrate is bonded to a second substrate via a joining layer.

Abstract: A method of coating a corner interface of a turbine system includes placing a mesh assembly proximate the corner interface. The method also includes depositing a coating onto and through the mesh assembly and into the corner interface, wherein the mesh assembly dampens a kinetic energy of the coating and secures the coating proximate the corner interface.

Abstract: A method for producing a component with at least one functional element includes providing a substrate; enriching a plasma jet with material of the at least one functional element to be formed; and applying at least one functional element on the substrate, in that material in at least essentially liquid form is applied by means of the enriched plasma jet, connected to the substrate and consolidated.

Abstract: A turbine blade for industrial gas turbine is used which includes a blade substrate formed of a single-crystal heat-resistant alloy containing C: 0.06 to 0.08%, B: 0.016 to 0.035%, Hf: 0.2 to 0.3%, Cr: 6.9 to 7.3%, Mo: 0.7 to 1.0%, W: 7.0 to 9.0%, Re: 1.2 to 1.6%, Ta: 8.5 to 9.5%, Nb: 0.6 to 1.0%, Al: 4.9 to 5.2%, Co: 0.8 to 1.2%, and the remainder substantially consisting of Ni with reference to mass, and includes a diffusion barrier layer, a metal layer, a bond coat, and a top coat, these layers and coats being stacked in this order on a surface of the blade substrate, the metal layer having a thickness of 5 to 30 ?m. Thus, the turbine blade can be provided which has a thermal barrier coating formed without loss of a function of the diffusion barrier layer.

Abstract: A method of modifying a boundary region (9) of a substrate (3) bounded by a surface (10), wherein an evacuated process chamber (2) is provided having a plasma source (4) for generating a directed plasma jet (5), and wherein furthermore a reactive component is supplied into the process chamber (2) with a flow of a predefined size, and wherein the substrate (3) is heated to a predefined reaction temperature, characterized in that the reactive component is diffusion-activated by the directed plasma jet (5) such that the reactive component diffuses into the boundary region (11) of the substrate (3) at a predefinable diffusion rate.

Abstract: There is provided a coating for a body of steel or a carbon fiber reinforced plastic material with an adhesion-promoting layer of thermoplastic that is deposited on the body, in the surface near material matrix of which solid particles are embedded in a form-fitting adhering manner such that a partial region of particles projects from the adhesion promoting layer. For producing such a coating, the adhesion-promoting layer is heated to a honey-like viscosity, and powder particles are injected by thermal spraying, into the surface near material matrix of the heated adhesion-promoting layer in a form-fitting adhering manner such that the tips of particles project. These tips connect to deposited powder particles which form the functional layer of oxide ceramic such as Al2O3, Cr2O3, TiO2, SiO2 or ZrO2 or mixtures therefrom and/or wear resistant hard metal such as WC/Co, Cr3C2/NiCr, NiCrBSi, WC/Ni, TiC/Ni, molybdenum, or chromium or mixtures or alloys thereof.

Abstract: A high purity ZrB2 powder having a purity of 99.9 wt % or higher excluding C and gas components, and a manufacturing method of such high purity ZrB2 powder, including the steps of: subjecting a Zr sponge raw material to electron beam melting and casting to prepare an ingot having a purity of 99.9 wt % or higher; cutting the ingot into a cut powder and hydrogenating the cut powder into ZrH2; pulverizing and dehydrogenating the resultant product into a Zr powder and oxidizing the Zr powder at a high temperature in an oxygen atmosphere into a ZrO2 fine powder; and mixing the ZrO2 fine powder with B having a purity of 99.9 wt % or higher so as to reduce ZrO2 and obtain a ZrB2 powder having a purity of 99.9 wt % or higher. Purity of the ZrB2 powder for use in sintering is made to be 99.

Abstract: A method for roughening and thermally coating a surface, in particular a cylinder running surface of an internal combustion engine, the roughening being the preparation of the surface for the thermal coating of the surface with a coating. The method is characterized in that different roughening profiles are introduced into the surface during the roughening and the coating has different properties distributed over the surface. This allows the coating or spraying process during the later thermal coating to be carried out with substantially constant spraying parameters. The different properties of the coating, such as hardness, porosity, machinability, chemical composition, oxidation and adhesion, are then obtained just on the basis of the differently roughened surface.

Abstract: A method and apparatus are described for very low pressure high powered magnetron sputtering of a coating onto a substrate. By the method of this invention, both substrate and coating target material are placed into an evacuable chamber, and the chamber pumped to vacuum. Thereafter a series of high impulse voltage pulses are applied to the target. Nearly simultaneously with each pulse, in one embodiment, a small cathodic arc source of the same material as the target is pulsed, triggering a plasma plume proximate to the surface of the target to thereby initiate the magnetron sputtering process. In another embodiment the plasma plume is generated using a pulsed laser aimed to strike an ablation target material positioned near the magnetron target surface.

Abstract: A method of coating a substrate surface. The method includes plasma spraying a direct-spray component onto a substrate surface, and plasma spraying an over-spray component onto the substrate surface. The direct-spray and over-spray components form a plasma coating surface contacting at least a portion of the substrate surface.

Abstract: A sampling cone of a mass spectrometer is disclosed having a metallic boride coating such as titanium diboride.

Abstract: A device, a method for marking a substrate (14) with a plasma generator (5) and a corresponding marking are disclosed. A plasma jet (11) is directed onto the substrate (14) and is superimposed with a powder jet (12). In a powder dosing and dispersing unit (7), a powder (20) and a marker substance (30) in powder form are mixed. The marking forms an adhesive layer (15) of the powder (20) material in which a marker substance (30) is homogeneously distributed and permanently embedded.

Abstract: An electrode thin film to be used in an all-solid lithium battery is formed predominantly of lithium cobaltate and has a density larger than or equal to 3.6 g/cm3 and smaller than or equal to 4.9 g/cm3.

Abstract: A method and apparatus for microplasma spray coating a portion of a turbine vane without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the turbine vane is coated with the powdered material without having to mask the turbine vane.

Abstract: To manufacture a ceramic article, a ceramic body comprising Al2O3 is roughened to a roughness of approximately 140 micro-inches (?in) to 240 ?in. The ceramic body is subsequently cleaned and then coated with a ceramic coating. The ceramic coating comprises a compound of Y4Al2O9 (YAM) and a solid solution of Y2-xZrxO3. The ceramic coating is then polished.

Abstract: Methods for depositing hardfacing material on portions of drill bits comprise providing a vertically oriented plasma transfer arc torch secured to a positioner having controllable movement in a substantially vertical plane. A rolling cutter is secured to a chuck mounted on an articulated arm of a robot. A surface of a tooth of the rolling cutter is positioned in a substantially perpendicular relationship beneath the torch. The torch is oscillated along a substantially horizontal axis. The rolling cutter is moved with the articulated arm of the robot in a plane beneath the oscillating torch. A hardfacing material is deposited on the tooth of the rolling cutter.

Abstract: A plasma spray method for the manufacture of an ion conducting membrane, in particular of a hydrogen ion conducting membrane or of an oxygen ion conducting membrane is suggested. In which method the membrane is deposited as a layer (11) on a substrate (10) in a process chamber, wherein a starting material (P) is sprayed onto a surface of the substrate (10) by means of a process gas (G) in the form of a process beam (2). The starting material is injected into a plasma at a low process pressure which is at most 10000 Pa and is partially or completely melted there. In accordance with the invention the substrate (10) has pores (30) which are connected amongst one another so that the substrate (10) is gas permeable and a portion of an overall pore area of an overall area of the coating surface (31, 131) amounts to at least 30%, in particular to at least 40%.

Abstract: A method of applying a barrier coating to a component is provided. The method includes providing the component and preparing a slurry comprising a mixture. The mixture includes about 50-90 percent by volume fraction of a barrier coating composition, the barrier coating composition and 10-50 percent by volume fraction of a plurality of short fibers. The method includes applying at least one layer of the slurry to at least a portion of the component and curing the slurry on the portion of the component to obtain a fiber-reinforced barrier coating.

Abstract: The present invention discloses a nano-crystalline ceramic structure coat of resistive material and a method thereof for a substrate. The coating method includes the use of a resistive material solution diluted to a composition that is capable of atomization into atomized vapor particles, and conveyance of the atomized vapor particles onto a substrate, forming a conformal layer of substantially dehydrated compound. Further application of thermal energy consolidates the conformal layer into a coating of the nano-crystalline ceramic structure, with enhanced ceramic bonding with the substrate.

Abstract: This invention relates to thermally sprayed coatings having an amorphous-nanocrystalline-microcrystalline composition structure, said thermally sprayed coating comprising from about 1 to about 95 volume percent of an amorphous phase, from about 1 to about 80 volume percent of a nanocrystalline phase, and from about 1 to about 90 volume percent of a microcrystalline phase, and wherein said amorphous phase, nanocrystalline phase and microcrystalline phase comprise about 100 volume percent of said thermally sprayed coating. This invention also relates to methods for producing the coatings, thermal spray processes for producing the coatings, and articles coated with the coatings. The thermally sprayed coatings of this invention provide enhanced wear and corrosion resistance for articles used in severe environments (e.g., landing gears, airframes, ball valves, gate valves (gates and seats), pot rolls, and work rolls for paper processing).

Abstract: The present invention is related to a method for depositing a coating on a substrate (2) by a flame-assisted chemical vapour deposition technique, wherein the substrate is exposed to a flame produced by a burner (1), while a flow of precursor elements is added to said flame, and wherein the substrate is subjected to a relative movement with respect to said burner wherein the flame is dragged out along a reaction zone (3) situated behind the burner, and wherein the relative speed of the substrate with respect to the flame is higher than 30 m/min.

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: A method of protecting a polymer surface against fouling, which method comprises embedding in the polymer surface particles having antifouling properties, wherein the particles are embedded in the polymer surface by a spray mechanism in which the particles are accelerated and sprayed onto the polymer surface with a suitable velocity such that the particles become embedded in the polymer surface, wherein the particles are embedded in the polymer surface without an adhesive or binder and wherein the particles do not form a continuous layer on the polymer surface.

Abstract: The present disclosure generally relates to systems, apparatus and methods of plasma spraying and plasma treatment of materials based on high specific energy molecular plasma gases that may be used to generate a selected plasma. The present disclosure is also relates to the design of plasma torches and plasma systems to optimize such methods.

Abstract: A plasma spray nozzle is provided. Owing to their high degree of wear, previous plasma spray nozzles were not suitable for the coating of components for which long coating times were necessary. The coating times may be reduced considerably by the triple injection of powder into the inner channel through the plasma spray nozzle.

Abstract: A method for coating a component, in particular a component of a gas turbine or of an aircraft engine, is disclosed. The coating is applied to the component by kinetic cold gas spraying, where prior to the deposition of the coating, the surface of the component to be coated is cleaned and compacted by shot peening with a blasting media. A component produced in this manner is also disclosed.

Abstract: The invention relates to a device for the qualitative and/or quantitative determination of at least one component of a chemically reducible gas mixture, an exhaust gas catalytic converter utilizing such a device, a vehicle including such a catalytic converter, a process for preparing such a device, a process for monitoring the NOx emissions of a vehicle, and the use of such a device.

Abstract: In a method for coating a substrate, a ceramic first layer is suspension plasma sprayed and is at least about as tough as 7YSZ. A ceramic second layer is applied over the first layer and is less tough than the first layer.

Abstract: A plasma spray method for the manufacture of an ion conducting membrane, in particular of a hydrogen ion conducting membrane or of an oxygen ion conducting membrane is suggested. In which method the membrane is deposited as a layer (11) on a substrate (10) in a process chamber, wherein a starting material (P) is sprayed onto a surface of the substrate (10) by means of a process gas (G) in the form of a process beam (2). The starting material is injected into a plasma at a low process pressure which is at most 10000 Pa and is partially or completely melted there. In accordance with the invention the substrate (10) has pores (30) which are connected amongst one another so that the substrate (10) is gas permeable and a portion of an overall pore area of an overall area of the coating surface (31, 131) amounts to at least 30%, in particular to at least 40%.

Abstract: A method for providing a coating layer with well protection and thermal conductivity, providing a coating layer material, the coating layer material set on a workpiece to form a coating layer with thickness 160˜500 micrometer. The coating layer is able to avoid wear of the surface of the workpiece, and has well protection and thermal conductivity, to avoid the situation of damage or mechanical property changing occurred due to the temperature of the surface rising caused by the friction.

Abstract: To apply a thermal barrier coating (10), a plasma jet (5) is generated by a plasma torch in a work chamber (2) and is directed to the surface of a substrate (3) introduced into the work chamber, and a ceramic coating material is applied to the substrate surface by means of PS-PVD, wherein the coating material is injected into the plasma jet as a powder and is partly or completely vaporized there. On applying the thermal barrier coating, in a first workstep the feed rate of the injected powder is set so that a large part of the injected powder vaporizes, wherein the coating material condenses from the vapor phase on the substrate surface and forms mixed phases with the material of the substrate surface.

Abstract: Provided is a method of fabricating, with satisfactory adhesion, a thin film of a metal or a metallic-compound, such as a metal oxide or nitride, on a substrate made of a high-melting-point material such as silicon or ceramics by using a metal or metallic-compound target as the primary raw material so as to eliminate the necessity of using harmful gases such as organometallic gas, and by using an atmospheric-pressure plasma generated under atmospheric pressure as a reaction field and also as a heat source. Additionally provided is an apparatus for fabricating the thin film.

Abstract: Molybdenum disulfide powders include substantially spherically-shaped particles of molybdenum disulfide that are formed from agglomerations of generally flake-like sub-particles. The molybdenum disulfide powders are flowable and exhibit uniform densities. Methods for producing a molybdenum disulfide powder may include the steps of: Providing a supply of molybdenum disulfide precursor material; providing a supply of a liquid; providing a supply of a binder; combining the molybdenum disulfide precursor material with the liquid and the binder to form a slurry; feeding the slurry into a stream of hot gas; and recovering the molybdenum disulfide powder, the molybdenum disulfide powder including substantially spherically-shaped particles of molybdenum disulfide formed from agglomerations of generally flake-like sub-particles.

Abstract: A process for producing a thermal barrier coating having an excellent thermal barrier effect and superior durability to thermal cycling. Also, a turbine member having a thermal barrier coating that has been formed using the production process, and a gas turbine. The process for producing a thermal barrier coating includes: forming a metal bonding layer (12) on a heat-resistant alloy substrate (11), and forming a ceramic layer (13) on the metal bonding layer (12) by thermal spraying of thermal spray particles having a particle size distribution in which the 10% cumulative particle size is not less than 30 ?m and not more than 100 ?m.

Abstract: A process of fabricating a thermal barrier coating and an article having a cold sprayed thermal barrier coating are disclosed. The process includes cold spraying ceramic particles and a binder and forming the thermal barrier coating. The binder has a melting point lower than the ceramic particles. The article includes the cold sprayed thermal barrier coating positioned on a substrate of the article and/or a reproducible feature formed by the cold sprayed thermal barrier coating, with the reproducible feature being capable of being replicated without masking.

Abstract: A process of fabricating a thermal barrier coating is disclosed. The process includes cold spraying a substrate with a feedstock to form a thermal barrier coating and concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating. The cold spraying is in a region having an oxygen concentration of at least 10%. In another embodiment, the process includes heating a feedstock with a laser and cold spraying a substrate with the feedstock to form a thermal barrier coating. At least a portion of the feedstock is retained in the thermal barrier coating. In another embodiment, the process of fabricating a thermal barrier coating includes heating a substrate with a laser and cold spraying the substrate with a feedstock to form a thermal barrier coating.

Abstract: An improved substrate is disclosed for an electrode of an electrochemical cell. The improved substrate includes a core material surrounded by a coating. The coating is amorphous such that the coating includes substantially no grain boundaries. The core material may be one of lead, fiber glass, and titanium. The coating may be one of lead, lead-dioxide, titanium nitride, and titanium dioxide. Further, an intermediate adhesion promoter surrounds the core material to enhance adhesion between the coating and the core material.

Abstract: A thermal spraying method is provided, wherein spray particles of a powdered spray material are introduced into a hot carrier gas stream, heated by the carrier gas stream and then sprayed onto the surface of a substrate by a spray nozzle, wherein the temperature of the spray particles upon impact onto the substrate is below the melting temperature of the spray material. The spray particles are heated in the hot carrier gas stream upstream of the nozzle throat to a temperature that causes at least partial melting of the spray particles in that location.

Abstract: An apparatus and methods for cold spraying with a spraying unit, a particle supply, a gas supply, and at least one heating unit. The heating unit contains a graphite felt that can be heated with an electric heater current, through which a gas stream can flow, wherein the at least one heating unit is arranged separately and/or in a pressure tank through which the gas stream can flow.

Abstract: Disclosed herein is an article having a surface modified to alter its surface tension property and increase resistance to sand abrasion as characterized by a material volume loss of less than 75 mm3 according to ASTM G65-04 Procedure B. In one embodiment of the method, an intermediate layer is first deposited onto a substrate of the article. At least a substrate on the article is protected by a coating layer, which comprises: an intermediate layer adjacent to the substrate with a thickness of at least 2 mils containing a plurality of pores with a total pore volume of 5 to 50% within a depth of at least 2 mils; and a surface layer comprising a lubricant material deposited onto the intermediate layer. The lubricant material infiltrates at least a portion of the pores for the coating to have the desired surface tension depending on the application.