Abstract: A combustor including a combustor lining, a tile including a recess at an end defining a receiving surface, and a tile holder. The tile holder includes an elongate retaining head having a combustor surface configured to face a combustion chamber of a combustor, and a securing portion extending from the head, the securing portion being configured to secure the head to a combustor lining. The retaining head extends laterally with respect to an elongate direction of the retaining head to define a retaining surface laterally adjacent to the securing portion; and the retaining surface cooperates with the receiving surface of the tile to retain the tile against the combustor lining. There is also disclosed a tile holder and a tile.

Abstract: A rotating machine component, particularly a gas turbine combustion component, having at least one part built from a porous material with a plurality of pores, wherein at least a subset of the plurality of pores is at least partly filled with a gas with a composition different from air and/or with a powder, wherein the porous material is a laser sintered or laser melted material in which void local regions form the plurality of pores. The component counter-acts vibrations. A rotating machine or gas turbine engine may have such a component.

Abstract: A seal runner adapted for use in a knife seal in a gas turbine engine is disclosed. The seal runner illustratively includes an abradable liner.

Abstract: A laser direct metal deposition method for a graphite substrate is provided. The laser direct metal deposition method includes creating an assembling by sliding an outer sheath over the graphite substrate. Further, laser direct metal deposition method includes performing a laser scanning of the outer sheath and performing a laser metal deposition over the graphite substrate with the outer sheath.

Abstract: A method for forming a metallic structure having a secondary component includes positioning the secondary component on a main formation surface of a main tool, the main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing a layer of material on the secondary component and the main formation surface using a cold-spray technique such that the layer of material bonds to the secondary component. The method also includes removing the layer of material and the secondary component to form the metallic structure.

Abstract: A surface of a piston and/or a cylinder head and/or a cylinder bore of an internal combustion cylinder with selectively applied plasma transferred wire arc coating which acts as a thermal barrier improving fuel efficiency and reducing fuel emissions and a method of producing the plasma transferred wire arc coating on a surface of a piston and/or cylinder head and/or a cylinder bore of a compression ignition and/or spark ignition engine.

Abstract: The present invention relates to a conditioning method of gas turbine engine components (e.g. compressor blades and vanes) for increasing fuel efficiency. The gas turbine engine components are plasma treated in a high vacuum environment to generally reach a surface roughness (Ra) below 150 nanometers and in some cases below 25 nanometers. Then during the same process the components are coated using either a metallic or ceramic, hard, thin coating ranging from 100 to 3000 nanometers in thickness depending on desired surface smoothness and non-fouling properties. The same treatment combined with a surface relaxation process, which is part of a smoothing process, allows applying even up to 100 micrometers of hard coating without changes to high cycle fatigue properties and overall performance. Improved surface smoothness of the components and enhanced non-adhesiveness of the contaminants advance the quality of the flow through the gas path and compressor efficiency.

Abstract: A bearing may include a substrate and a metallic layer disposed in contact with the substrate. An adhesive layer may be disposed in contact with the metallic layer. A supporting layer may be disposed in contact with the adhesive layer. According to an example, a polymer layer may be disposed in contact with the adhesive layer. According to another example, a polymer layer may be disposed in contact with the supporting layer.

Abstract: The present invention relates to a method for producing bearing shells of plain bearings, in which the bearing shells are blasted with corundum particles on the bearing metal side, in order in this way to produce residual compressive stresses in the blasted side of the bearing shell. Furthermore, the present invention relates to a bearing shell produced using such a method.

Abstract: A method is provided of processing substrate holder material for a substrate holder on which on a first side of said substrate holder a semiconductor substrate is to be placed for layered deposition of various semiconductor materials on the semiconductor substrate using induction heating. The method includes the operations of determining a first electrical resistivity at at least one measuring position on said substrate holder material, comparing said first electrical resistivity with a second reference electrical resistivity and adapting said substrate holder material in correspondence with said comparison. Also a substrate holder is provided which is processes by such a method.

Abstract: An optical power-limiting passive (self-adaptive) device and method for limiting optical power transmission in lenses and windows, using layers of different photochromic compositions that exploit the full solar ultraviolet (UV) and short visible light spectrum. While a typical single photochromic material is activated by a UV band of wavelengths, e.g. 340 to 380 nm, adding a layer of photochromic material that is activated by an additional band of wavelengths, e.g., 380 to 420 nm, allows the efficient use of a wider band of solar UV and short visible light, e.g., 340 to 420 nm, thus enhancing the photochromic response to solar light.

Abstract: The present invention is a coated article containing at least two adjacent cooling holes that are substantially uncoated. In an embodiment, the coated article includes a base material, an outer surface and a coating on a portion of the outer surface. Here, the adjacent cooling holes are arranged along an axis on the outer surface and extend within the base material at an angle to the outer surface. The coating may include at least one unfinished edge oriented substantially parallel to the axis and set off at an oblique angle and a distance from the adjacent cooling holes.

Abstract: A method for the formation of channels on a metallic substrate is described. The method includes the steps of applying at least one layer of a metallic coating material onto a surface of the substrate by a cold spray technique, so as to define boundary walls for the channels, and to build the boundary walls to a desired height. Additional coating material is then applied on one or more surfaces of the boundary walls by the cold spray technique, so as to modify the shape of the channels. The substrate can be any type of high-temperature component or hot gas path component. In some instances, the substrate is a gas turbine engine wall.

Abstract: Embodiments involve smart device fabrication for semiconductor processing tools via precision patterning. In one embodiment, a method of manufacturing a semiconductor processing tool component includes providing a substrate of the semiconductor processing tool component, patterning the substrate to form a sensor directly on the substrate, and depositing a top layer over the sensor. The sensor may include, for example, a temperature or strain sensor. The method can also include patterning the substrate to form one or more of: heaters, thermistors, and electrodes on the substrate. In one embodiment, the method involves patterning a surface of the component oriented towards a plasma region inside of the semiconductor processing tool.

Abstract: Disclosed herein are consumer electronics housings made from bulk-solidifying amorphous alloy materials having a ductile coating applied to all or a portion of the bulk-solidifying amorphous alloy. Also disclosed are methods of making consumer electronic housings from bulk-solidifying amorphous alloy materials such that at least a portion of the bulk-solidifying amorphous alloy housing is coated with a ductile cladding material.

Abstract: Provided is a method for manufacturing an acoustic wave device that has an excellent temperature coefficient of frequency (TCF) and high accuracy of IDT pattern forming and is capable of resisting high temperature processing of 200 degrees or more. The method for manufacturing an acoustic wave device according to the present invention includes forming an IDT (2) on a principal surface (1a) of a piezoelectric substrate (1), and forming a film by thermal spraying a material (3) having a smaller linear thermal expansion coefficient than the piezoelectric substrate onto an opposite principal surface (1b) of the piezoelectric substrate (1) where the IDT (2) is formed.

Abstract: A vibration layer is formed by the AD method on a cavity plate before forming pressure chambers, a common electrode is formed on the vibration layer, and a piezoelectric layer is formed on the common electrode by the AD method. Subsequently, the pressure chambers are formed in the cavity plate by the etching. After that, individual electrodes are formed on the piezoelectric layer. Subsequently, the stack of the cavity plate, the vibration layer, the common electrode, the piezoelectric layer, and the individual electrodes is heated at about 850° C. to simultaneously perform the annealing of the piezoelectric layer and the sintering of the individual electrodes and the common electrode. Accordingly, the atoms of the cavity plate are suppressed from being diffused into the driving portions of the piezoelectric layer.

Abstract: In a method for a finishing work of a spray-coated surface, an inner surface of a cylindrical hollow member is roughened by forming a helical groove thereon. A thermal spray coating is formed on the inner surface that is roughened, and a finishing work is carried out by cutting the thermal spray coating along a helix of the groove by use of a cutting tool. According to the method for a finishing work, a finishing work of a thermal spray coating with non-uniform hardness can be carried out efficiently.

Abstract: The present invention relates to a road finisher comprising a screed plate and/or a tamper bar and also to a screed plate and/or tamper bar comprising a heating layer applied by thermal spraying.

Abstract: A substrate mounting table includes a plate shaped member provided with a mounting surface for mounting a substrate thereon, a plurality of gas injection openings opened on the mounting surface to supply a gas toward the mounting surface, and a gas supply channel for supplying the gas through the gas injection openings; and a thermally sprayed ceramic layer covering the mounting surface. At least inner wall portions of the gas supply channel are formed in curved surface shapes, the inner wall portions facing the gas injection openings.

Abstract: A gas turbine engine includes airfoils. At least a portion of the airfoils are coated with a coating that provides for erosion and corrosion protection for the portion of the airfoils.

Abstract: A method and apparatus for cleaning a process chamber are provided. In one embodiment, a process chamber is provided that includes a remote plasma source and a processing chamber. The processing chamber includes a substrate support assembly disposed in the bottom portion of the processing chamber, a gas distribution system configured to provide gas into the processing chamber above the substrate support assembly, a removable liner layer the chamber interior walls. An adhesion layer is disposed on the substrate support. A protective layer is disposed on the adhesion layer. Pluralities of intermediate layers are created between the substrate support layer and the adhesion layer, and the adhesion layer and the protective layer through a thermal treatment in a non-reactive environment.

Abstract: Methods for coating a metal substrate with electrically conductive dots or splats of active materials for use in battery applications that improve the corrosion resistant metallic component electrode activity, or electrical conductivity of those components at reduced or lower costs.

Abstract: A plasma gun system comprising: a plasma gun comprising an outlet, wherein the plasma gun is configured to generate a plasma stream and provide the plasma stream to the outlet; and a plasma gun extension assembly configured to be coupled to the plasma gun, wherein the plasma gun extension assembly comprises an extension chamber and a port, the extension chamber having an interior diameter defined by a chamber wall and being configured to receive the plasma stream from the outlet of the plasma gun and to enable the plasma stream to expand upon entering the extension chamber, and the port being configured to introduce a powder to the expanded plasma stream at a location outside of the plasma gun.

Abstract: Methods of pressure coating a target surface of an article comprising one or more grooves formed in an outer surface of an article include fluidly connecting a pressure masker comprising a pressurized masking fluid to one or more coolant supply holes on a first side of the article. The one or more coolant supply holes in fluidic communication with the one or more grooves. Passing the pressurized masking fluid through the one or more grooves from the first side to a second side comprising the target surface at a pressure less than the coating pressure of the coating material, and, coating the target surface with the coating material to allow the coating material to bridge over the one or more grooves and form one or more micro-channels. The pressurized masking fluid passing through the one or more grooves prevents the coating material from permanently altering a cross sectional area of the one or more grooves along its length.

Abstract: A method of making a reinforcement for reinforcing a leading edge of a blade, the method including depositing a metal coating on the leading edge by thermal spraying in compression. A blade, for example a blade for a turbine engine, a helicopter, or a propeller, can have the leading edge protected by such a reinforcement.

Abstract: A low-cost integrated reflector and heat spreader for high-density high power solid-state (e.g., LED) lighting arrays includes a base structure onto which is applied a sacrificial material. A relatively thick thermal spray coating is applied over the base structure and sacrificial material. The sacrificial material is removed. A channel(s) is thereby provided within the thermal spray coating layer and in physical contact with the base structure. The channel may be filled with a cooling fluid. A pulsating heat pipe heat spreader may thereby be provided. A reflective material may be provided either over another surface of the base structure or alternatively over the thermal spray coating layer to provide a surface for reflecting and directing light emitted from a solid state light source that may be secured to the integrated reflector and heat spreader.

Abstract: A method of coating a surface is provided. The method comprises feeding a feedstock to a thermal spray torch, the feedstock comprising a liquid, disposing the feedstock on a substrate by thermal spray under conditions selected to produce a textured surface comprising a hierarchical structure, wherein the hierarchical structure comprises agglomerations of at least partially melted and solidified particles derived from the feedstock with individual at least partially melted and solidified particles derived from the feedstock disposed on a surface of the agglomerations; and applying a surface energy modification material over the textured surface. An article comprising a component having a coated surface is also provided.

Abstract: The present invention provides a method of applying a coating to a perforated substrate, the method comprising: (a) providing a perforated substrate having a substrate first surface, a substrate second surface and one or more perforations traversing the substrate from the first surface to the second surface; (b) bringing the substrate first surface into contact with a perforation blocking solid; (c) applying a metallic thermal spray coating composition to the substrate second surface using a thermal spray technique; and (d) separating the perforation blocking solid from the substrate first surface to provide a substrate having a metallic thermal spray coating disposed upon the substrate second surface and wherein the perforations are not occluded by the metallic thermal spray coating. Among its many other uses, the method is also useful for applying thermal spray coatings to the interior surface of valve cages used in flow control valves.

Abstract: A method of manufacturing a thermal barrier coated article including: forming an article having a first and second surface, the article having projections extending from the first surface away from the first and second surface, each projection having a first end adjacent the first surface and a second end remote from the first surface, each projection having a blind passage extending therethrough from the second surface through the article towards the second end of the projection, the blind passage in the projection being closed at the second end of the projection, depositing a thermal barrier coating on the first surface around each of the projections and on the second ends, removing the thermal barrier coating from the second ends, and removing the second end of each projection to form a passage through the projection extending from the second surface through the article to the second end of the projection.

Abstract: In one aspect, a method of forming a hot gas path component is provided. The method includes forming at least one groove in an outer surface of a substrate, wherein the at least one groove has a base and a top. The method further includes filling the at least one groove with a filler. The method also includes applying at least one cover layer over at least a portion of the outer surface of the substrate such that the at least one groove and the at least one cover layer define at least one micro-channel for cooling the component. The filler is automatically removed from the at least one micro-channel during application of the at least one cover layer. Methods for coating a hot gas component and for assembling a turbine engine assembly are also provided.

Abstract: A zirconium alloy nuclear reactor cylindrical cladding has an inner Zr substrate surface (10), an outer volume of protective material (22), and an integrated middle volume (20) of zirconium oxide, zirconium and protective material, where the protective material is applied by impaction at a velocity greater than 340 meters/second to provide the integrated middle volume (20) resulting in structural integrity for the cladding.

Abstract: A method for applying a fixed image onto at least one surface of a component in an electrochemical device is described. The component is usually formed of an alumina material. An image-forming material is first applied onto the component surface in its green state. The mark or image is applied in a desired pattern by an additive process, such as direct-write or screen-printing. The component is then heated at a sintering temperature sufficient to ensure conversion from the green state into a fired ceramic state. The sintering temperatures are also sufficient to fix the image upon the surface of the component. The image can be read by the human eye, or by various machine-readable techniques. Related methods for monitoring the location and status of a ceramic electrochemical cell component during its manufacture and during other processing steps are also described.

Abstract: Disclosed are a thermal spray coating material which greatly improves corrosion resistance, as compared to conventional Al2O3 and Y2O3 crystalline coatings and Al—Y—O and Al—Zr—O amorphous thermal spray coatings, a production method of the coating material, and a coating method using the same. The thermal spray coating material has a chemical formula of Y2xZr1-xOx+2, where x ranges from 0.19 to 0.83, preferably from 0.35 to 0.69. Accordingly, it is possible to produce a coating material for use in a chamber of vacuum plasmas equipment or internal parts of the chamber can be produced, which improves the corrosion resistance of a protective coating film upon ceramic thermal spray coating and lengthens the lifespan of parts.

Abstract: An electrically conductive resistive layer is produced by thermally spraying an electrically conductive material onto the surface of a non-conductive substrate. Initially, the material layer arising therefrom has no desired shape. The material layer is then removed in certain areas so that an electrically conductive resistive layer having said desired shape is produced.

Abstract: A method of manufacturing a thermal barrier coated article including the steps of: a) forming an article having a first surface and a second surface, the article having a plurality of projections extending from the first surface in a direction away from the first surface and away from the second surface, each projection having a first end adjacent the first surface and a second end remote from the first surface, b) depositing a thermal barrier coating on the first surface of the article around each of the projections and on the second ends of the projections, c) removing the thermal barrier coating from the second ends of the projections, and d) forming at least one passage through each projection extending from the second surface of the article through the article and through the respective projection to the second end of the respective projection.

Abstract: A bogie shaft for railway vehicles has a cladding which contains a metal component. The metal component is preferably electrochemically less refined, but no greater than exactly as refined, as a material of the bogie shaft. Corrosion on the bogie shaft can thereby be advantageously prevented. The metal material of the cladding is also able to effectively protect the bogie shaft against stone impact. The cladding can be advantageously applied by cold gas spraying, or a sleeve can be bent around the bogie shaft for forming the cladding. The cladding can advantageously contain particles that can make it more resistant to stone impact. The particles can be made, for example, of hard materials, of particularly ductile particles, or of particles made of a memory shape alloy.

Abstract: A method of coating a surface of a substrate with a particulate coating material, the method comprising: determining at least an area of the surface of the substrate to be covered with the particulate coating material; subjecting at least a portion of the area of the surface of the substrate to laser irradiation to form a plurality of distinct spaced-apart laser impact craters in a pattern and/or at least one last impact pit on the surface of the substrate; and thermally spraying the area of the surface of the substrate with the particulate coating material. A coated substrate comprising: a substrate having a plurality of distinct spaced-apart laser impact craters in a pattern and/or at least one laser impact pit on at least an area of a surface of the substrate; a thermally-sprayed coating mechanically bonded to at least the area of the surface of the substrate.

Abstract: A thermal coating method for applying a functional layer to a workpiece surface, particularly for applying a running surface coating to a cylinder running surface of a crankcase of an internal-combustion engine, includes the steps of: melting a coating material by use of a melting device, applying coating material droplets to the workpiece surface by use of a gas jet aimed at the workpiece surface, which gas jet blows coating material droplets from a melting location of the melting device onto the workpiece surface, and cooling or rapidly freezing the coating material droplets during their transport from the melting location to the workpiece surface.

Abstract: In one embodiment, a method for forming a metallized ceramic includes thermal spraying metal directly onto a first side of a ceramic plate. The metal comprising aluminum. The method also includes densifying the thermally ceramic plate after spraying the metal onto the first side of the ceramic plate.

Abstract: A method of producing a composite plasma spray coating using simultaneous feeding of powder and solution precursor feedstock in a plasma spray gun is disclosed, comprising the steps of a) spraying a powder feedstock comprising micron sized particles into a plasma spray plume; and b) spraying a liquid feedstock comprising liquid precursor solution into the plasma spray plume, wherein the spraying of the powder feedstock and spraying of the liquid feedstock are independently controllable. The method allows control of coating composition and microstructure to deposit nanostructured and microstructured layers either sequentially to form layered coatings, or simultaneously to form either composite coatings or continuously gradient coatings to address diverse applications. Thermal barrier coatings produced using the new method have demonstrated twice the life compared to conventional air plasma sprayed coatings.

Abstract: An apparatus for forming an amorphous coating film by jetting flame containing particles of a flame spray material from a flame spray gun toward a base material, causing the particles to be melted by the flame, and cooling both the particles and the flame with the means of a cooling gas before they reach the base material. The apparatus includes a tubular member provided among the path along which the flame is jetted that it surrounds the flame passing through a melting zone in which the particles are melted. The tubular member has a flow channel for the cooling gas, formed along and integrally to the tubular member.

Abstract: A method and system for depositing multiple materials onto a substrate is described. The method broadly comprises the steps of providing a source of a first powder material to be deposited, providing a source of a second powder material to be deposited, and sequentially depositing the first powder material and the second powder material onto the substrate at a velocity sufficient to deposit the materials by plastically deforming the materials without metallurgically transforming the particles of powder forming the materials.

Abstract: In a method for coating a work piece, a layer is electrochemically produced from a first material. In order to generate an inhomogeneous expansion behavior of the layer, a thermal spraying, in particular a cold gas spraying, achieves that specific zones are created in the layer from a material having a different thermal expansion behavior. These zones expand more laterally than in the direction of the layer thickness so that directed internal stresses occur in the layer upon heating or cooling of the component, which can be specifically utilized depending on the design conditions of the component.

Abstract: A method of forming a thermocouple (12), including: depositing a first material on a component (10) to form a first leg (14); depositing a second material through a mask (30) to form a pattern (50) on the component (10), the pattern (50) forming a plurality of discrete second leg junction ends (20) and a continuous patch (52) of the second material comprising indiscrete lead ends of the second legs (16), each second leg junction end (20) spanning from a respective junction (18) with the first leg (14) to the continuous patch (52); and laser-ablating the continuous patch (52) to form discrete lead ends (22) of the second legs (16), each lead end (22) electrically connected to a respective junction end (20), thereby forming discrete second legs (16).

Abstract: In the presented method for the manufacture of a thermal barrier coating structure (2) on a substrate surface (3) a ceramic coating material is applied onto the substrate surface by means of plasma spraying, wherein the thermal barrier coating structure includes at least two differently produced thermal barrier coatings (2.1, 2.2). For the manufacture of the one thermal barrier coating (2.1), the coating material is sprayed onto the substrate surface in the form of a powder jet by plasma spraying at atmospheric pressure (atmospheric plasma spraying or in abbreviation APS), and for the manufacture of the other thermal barrier coating (2.2) the coating material is applied onto the substrate surface by means of plasma spraying-physical vapor deposition or in abbreviation PS-PVD, such that a layer having elongate corpuscles develops on the substrate surface, which corpuscles form an anisotropic microstructure and are aligned essentially perpendicular to the substrate surface.

Abstract: A method and an apparatus for spraying a track, in particular a conductor track, onto a substrate under mild conditions, includes generating a cold plasma having a plasma temperature of less than 3000 K in a spray lance, introducing a powder into the spray lance with the aid of a carrier gas and leading the powder to a frontal exit opening, where it exits and impinges on the substrate. An electrical component including an electrically conductive conductor track applied to a substrate, is also provided.

Abstract: The invention relates to a method for producing a bearing component (1), in particular a connecting rod (1), from a molded part (2), wherein the bearing component (1) includes at least one divided bearing seat (5) formed by a bearing base (3) and a bearing cover (4), and a bearing seat surface (7) coated with a bearing layer (6) of a bearing layer material is formed in the bearing seat (5) for supporting a shaft. In the method of the present invention the bearing cover (4) is separated from the molded part (2) along a separating surface (8). In accordance with the invention, a masking agent (M) is disposed perpendicularly with respect to a separating line (10) on the bearing seat surface (7) during a coating process for applying the bearing layer (6) in order to form a coating-free region, such that a recess (9) at a predetermined width (B) is produced in the bearing layer (6). The masking agent (M) is formed as an element which is separate from the bearing component (1) and is not connected thereto.

Abstract: A method for coating a part includes applying a ceramic mask to a first surface portion of the part. A coating is applied to a second surface portion of the part and at least partially contacting the mask. The mask is destructively removed.

Abstract: A low-cost integrated reflector and heat spreader for high-density high power solid-state (e.g., LED) lighting arrays includes a base structure onto which is applied a sacrificial material. A relatively thick thermal spray coating is applied over the base structure and sacrificial material. The sacrificial material is removed. A channel(s) is thereby provided within the thermal spray coating layer and in physical contact with the base structure. The channel may be filled with a cooling fluid. A pulsating heat pipe heat spreader may thereby be provided. A reflective material may be provided either over another surface of the base structure or alternatively over the thermal spray coating layer to provide a surface for reflecting and directing light emitted from a solid state light source that may be secured to the integrated reflector and heat spreader.