Abstract: Methods and apparatus for the preparation and use of a substrate having an array of diverse materials in predefined regions thereon. A substrate having an array of diverse materials thereon is generally prepared by delivering components of materials to predefined regions on a substrate, and simultaneously reacting the components to form at least two materials. Materials which can be prepared using the methods and apparatus of the present invention include, for example, covalent network solids, ionic solids and molecular solids. More particularly, materials which can be prepared using the methods and apparatus of the present invention include, for example, inorganic materials, intermetallic materials, metal alloys, ceramic materials, organic materials, organometallic materials, non-biological organic polymers, composite materials (e.g., inorganic composites, organic composites, or combinations thereof), etc.

Abstract: A method for chemical vapor deposition using a very fine atomization or vaporization of a reagent containing liquid or liquid-like fluid near its supercritical temperature, where the resulting atomized or vaporized solution is entered into a flame or a plasma torch, and a powder is formed or a coating is deposited onto a substrate. The combustion flame can be stable from 10 torr to multiple atmospheres, and provides the energetic environment in which the reagent contained within the fluid can be reacted to form the desired powder or coating material on a substrate. The plasma torch likewise produces the required energy environment, but, unlike the flame, no oxidizer is needed so materials stable in only very low oxygen partial pressures can be formed.

Abstract: In order to provide a heat pipe for transporting heat from an evaporation area to a condensation area, comprising a housing with housing walls, a capillary structure arranged in the housing and thermally coupled to the respective, corresponding housing wall in the evaporation area as well as in the condensation area, a vapor channel arranged in the housing and leading from the evaporation area to the condensation area as well as a heat transport medium, as well to make available a process for the production of such a heat pipe it is suggested that the capillary structure be an open-pored capillary layer produced by way of thermal plasma spraying of powder particles.

Abstract: A method and shield assembly 12 for use in processing a flow directing assembly 10, such as a stator vane or rotor blade, is disclosed. Various details are developed for the construction of the shield assembly and for the method of masking the flow directing assembly. The shield assembly has a shield having two sides 52, 56 and at least one tab 56 which extends from one of the sides and through the other side and is pressed against the other side. In one embodiment, the method includes exerting a force against the shield to block movement of the shield from the installed position. The shield assembly might include a locking member for this purpose which has a projection 106a which is attached to the shield or a locking member 42 which is not attached to the shield and which has a tab 114 which engages the shield and a projection 112 which engages the airfoil. Alternatively, the shield assembly might include a clamp 92 which presses the shield against the airfoil.

Abstract: A roughened bond coat comprises a screen that includes interwoven wires defining openings and a metallic material disposed on the screen. The screen and metallic material form a roughened bond coat possessing an uneven, undulated, and irregular surface. The metallic material may be one of a slurry and a powder, and applied by coating and spraying, respectively. A thermal barrier coating system, which is formed with and incorporates the roughened bond coat, exhibits greater adhesion of a thermal barrier coating and bond coat due to an increased interfacial surface area provided by the uneven, undulated, and irregular surface.

Abstract: A locking member for engaging a shield 40 which is disposed during processing about an airfoil 24 of a flow directing assembly 10, such as a stator vane or rotor blade, is disclosed. Various details are developed for the construction of the locking member. In one embodiment, the locking member is separate from the shield and has projections 112, 116 that each engage an opening 36a, 36b in the airfoil and tabs 114, 118 which engage an opening 78, 84 in the shield. In another embodiment, the shield has a projection 106a which is attached to the shield.

Abstract: A light-reflective decorative glittered article is made by coating a light reflective foil with a powdered resin, fixing the resin, cutting the coated foil into glitter flakes, flocking the flakes onto a curable adhesive applied on areas of a base material to be decorated, and curing the adhesive while concomitantly causing the resin on contacting flakes to become tacky Scattering and fall-off of the flakes during manufacture are reduced.

Abstract: A method for hard facing a tool. The method is carried out by thermally spraying the tool with a composition which includes between 11/2%-10% carbon, 0-3% fluorides, 11/2-5% boron, 20-40% chromium, 1-15% nickel and the remainder iron. The resulting coated tool has exceptional wear resistance and bond strength, especially for ground engaging tools.

Abstract: A shield 40 for use in processing a flow directing assembly 10, such as a stator vane or rotor blade, is disclosed. Various construction details are developed for the shield. The shield has two sides 52, 56 and at least two tabs 56, 58 which each extend from one of the sides and through the other side.

Abstract: Protective and security coatings are applied to an integrated circuit by periodically passing the integrated circuit through a flame spray containing molten particles of the coating composition. The integrated circuit is attached to a fixture that is cooled with a coolant that is applied to the integrated circuit. The distance between the flame spray gun and the integrated circuit is controlled so that the particles are molten when they strike the circuit but the circuit heating is minimized. A flame resistant mask retains the integrated circuit on the fixture. The mask is constructed of a low thermally conductive material and the fixture is constructed of a high thermally conducive material.

Abstract: A method of preparing electrodes is now described, which electrodes have enhanced adhesion of subsequently applied coatings combined with excellent coating service life. In the method, a substrate metal, such as a valve metal as represented by titanium, is provided with a highly desirable rough surface characteristic for subsequent coating application. This can be achieved by various operations including etching to ensure a roughened surface morphology. In subsequent operations, a barrier layer is provided on the surface of enhanced morphology. This may be achieved by operations including heating, as well as including thermal decomposition of a layer precursor. Subsequent coatings provide enhanced lifetime even in the most rugged commercial environments.

Abstract: A shield 98 and method of shielding an airfoil 44 is disclosed. Various construction details are developed which increase the effectiveness of the shield and its reusability. In one embodiment, the shield has a plurality of interdigitated tabs 112,118 which urge the shield against the airfoil surfaces 94,96.

Abstract: The invention relates to layered bodies for absorbing water and aqueous liquids, consisting of at least one water-soluble polymer foam layer and particulate superabsorbent polymerizates, which contain the superabsorber on top of, between or underneath the foamed polymer layer in a quantitatively and/or locally predetermined and fixed sheet-like arrangement at a quantity ratio of polymer foam and superabsorber of from 1:500 to 50:1. The polymer foam may contain fillers, pigments and/or synthetic fibers. The layered bodies have increased absorptive capacity for water and aqueous liquids, particularly under load. They are produced by spreading the foam in a sheet-like fashion, applying the superabsorber at the predetermined quantity ratio, optionally using a template, and fixing it by a heat treatment.

Abstract: Methods and apparatus for the preparation and use of a substrate having an array of diverse materials in predefined regions thereon. A substrate having an array of diverse materials thereon is generally prepared by delivering components of materials to predefined regions on a substrate, and simultaneously reacting the components to form at least two materials. Materials which can be prepared using the methods and apparatus of the present invention include, for example, covalent network solids, ionic solids and molecular solids. More particularly, materials which can be prepared using the methods and apparatus of the present invention include, for example, inorganic materials, intermetallic materials, metal alloys, ceramic materials, organic materials, organometallic materials, non-biological organic polymers, composite materials (e.g., inorganic composites, organic composites, or combinations thereof), etc.

Abstract: A process for manufacturing wear and corrosion-protected surfaces on plasticized screws for injection molding machines forms the wear-resistent layers over the entire screw surface in two steps. A laser technique is used to melt additives into the surfaces of the screw rib, flank and top as well as the screw base by high-speed flame spring with hard metallic and/or ceramic substances.

Abstract: This invention consists of a coating that is zebra mussel resistant and biofouling resistant without dependence on copper leaching. The coating is a solid solution of copper and nickel containing at least 65 percent copper. Application of the coating to stationary screens, traveling water screens, trash racks, louvers, and other components of water withdrawal and hydroelectric systems, netting and other porous materials used in barrier nets, fish nets, aquaculture, and fish hatcheries, the bottoms of water craft including recreational craft, boats, and ships and on bouys, piers and pilings and other materials that might benefit from resistance to the attachment of zebra mussels and other aquatic or marine organisms.

Abstract: A method for applying a coating to the tips 46 of an array of flow directing assemblies 42 such as an array of rotor blades or stator vanes is disclosed. various steps in the method are developed which decrease cost and increase the efficiency of the method. In one particular embodiment, the step of surface preparation and coating applications are performed with the same fixture without removing or reinstalling the assemblies.

Abstract: A printed circuit board is formed by selectively conditioning at least one surface of a substrate with a pattern including selected areas conditioned to receiving metal, and non-selected areas to which metal will not adhere; the surface is then plasma sprayed with metal to coat the selectively prepared areas.

Abstract: A printed circuit board is formed by preparing at least one surface of a substrate with a pattern including selected areas for receiving metal, and non-selected areas to which metal will not adhere; the surface is then plasma sprayed with metal to coat the selected areas.

Abstract: A process for producing a coating on the surface of a plastifier screw for injection molding machines includes applying to a hard-metallic or ceramic substrate with low distortion, a steel screw base element, by high-speed flame spraying. During the coating process, a spray jet treats the different surface regions of the screw base element including the flanks and top of a rib as well as the base of the screw, independently.

Abstract: The invention provides a method of treating an artifact to combat unauthorized tampering with the identity thereof. The method comprises forming a coating on at least part of a surface of the artifact, to provide the artifact with an identification mark which comprises said coating. Forming the coating is by means of thermal spray-coating. The method can be used to coat a pre-formed identification mark on the surface, or to apply an identification mark to the surface, the mark being an engine number, chassis number, or the like. The method acts to render vehicle or aircraft theft, and forgery of parts thereof, more difficult.

Abstract: The invention is to a method for producing a high surface substrate. A mask is positioned (31) over a substrate to define a deposition area. Thereafter at least two dissimilar materials are simultaneously deposited (32) through the mask onto the deposition area. Then one of the deposited materials is selectively removed (33) to provide a high surface area deposited substrate.

Abstract: A method of making coater and doctor blades for use on paper-making machinery is disclosed. A bond coating and then a wear-resistant coating are applied to one edge of an endless steel carrier strip. The strip is passed together with a masking strip continuously in only one direction through a coating zone for spraying by a plasma gun. The masking strip masks a transverse portion of the carrier strip so as to leave one edge of the latter exposed to the spray. Spraying continues for the number of passes necessary to apply desired thicknesses of the coatings to the carrier strip.

Abstract: A plated vehicle wheel having non-plated tire bead seats and a process for forming same. The process includes masking a portion of the tire bead seats before plating the wheel. The process also includes forming the tire bead seats with an oversized diameter. Following plating, the tire bead seats are machined to a final diameter. The process can further include thermally depositing a layer of a ceramic material over a portion of the tire bead seat surface. The plating does not adhere to the ceramic material.

Abstract: A metal detector and distance sensor for a motor vehicle. A departure of the motor vehicle from a correct path indicated by one or two metal lines covered with paint in the road is signaled. The metals lines are formed by projecting a jet of metal in the gaseous state at high speed onto the road surface. A covering of paint is then formed over the metal line on the road surface. A turbine supplied by an air compressor projects the jet of metal in the gaseous state from a vehicle or a trailer having a metal supply device and a painting device thereon. A display indicates the direction of departure from the correct path and the distance separating the motor vehicle from a preceding vehicle. Alarm signals can be emitted upon the departure.

Abstract: Particles of a lens coating material for forming a primary film are deposited from a direction toward which the surfaces of the lens prisms of a Fresnel lens face. Next, a light absorbing film is formed, conventionally, by sputtering, on both the lens surfaces on which the previously deposited primary film was formed and on the non-lens surfaces (on which no primary film was formed). This light absorbing film is intended to absorb types of undesirable or "invalid" light (e.g., "flaring light"). Subsequently, the films are removed from only the lens surfaces. Accordingly, a Fresnel lens having "invalid" light absorbing films only on the non-lens surfaces is more easily fabricated within a shorter time and at a reduced cost. Moreover, it is also possible to reduce the generation of "cone" and "rainbow" effects caused by "flaring light" when the Fresnel lens is used as a field lens of a projection-type image display device.

Abstract: A method of preparing electrodes is now described, which electrodes have enhanced adhesion of subsequently applied coatings combined with excellent coating service life. In the method, a substrate metal, such as a valve metal as represented by titanium, is provided with a highly desirable rough surface characteristic for subsequent coating application. This can be achieved by various operations including etching to ensure a roughened surface morphology. In subsequent operations, a barrier layer is provided on the surface of enhanced morphology. This may be achieved by operations including heating, as well as including thermal decomposition of a layer precursor. Subsequent coatings provide enhanced lifetime even in the most rugged commercial environments.

Abstract: The invention relates to a process for producing a strong bond between copper layers, which have been applied by means of thermal spraying of pulverulent copper or copper alloys, and ceramic. Fine copper powder having a mean particle diameter of .ltoreq.20 .mu.m is applied to the ceramic surface by means of thermal spraying.

Abstract: Disclosed is a structure composed of a ragged base body with a ragged surface and a non-adhesive layer of a non-adhesive high polymer, in which the layer is fixed to at least the depressions of the ragged surface in such a way that the ragged profile of the body appears on the outer surface, reiterated by the layer. The ragged profile has a mean surface roughness Ra of 0.5 to 20 .mu.m and the mean distance Z between the adjacent projections forming the ragged profile is 20 to 1000 .mu.m. The non-adhesive high polymer may be a silicone high polymer having a silicone oil content of 10% or less. It has an effective surface tension of 32 dyn/cm or less. As the structure has improved releasing characteristics, adhesion of an adhesive substance to the structure may be effectively prevented without using any conventional releasing agent.

Abstract: The invention relates to a process for coating or hardfacing recharging a part by means of a plasma transferred arc.According to the process, on the part (1) to be coated or hardface is deposited at least one weld bead (7a, 7b, 7c) of said material solely by means of the plasma transferred arc (5), by moving the plasma relative to the part at a speed of 1.5 to 50 m/min and using a power of the plasma such that the surface of the part is melted over a thickness at the most equal to 0.5 mm and so that the enlargement of the grains in the melted area does not exceed 10%, without cooling the part during recharging.

Abstract: A texture treatment for a carbon substrate of a magnetic disk or for a carbon overcoat layer of a magnetic disk is effective to prevent the generation of a stiction phenomenon between a magnetic head and the surface of a magnetic disk. The texture treatment for a carbon substrate or carbon overcoat of a magnetic disk involves the steps of: preparing the carbon disk surface; forming a catalytic material layer on the surface; and performing a heat treatment of the disks in an oxidizing atmosphere. Preferably, islands of catalytic material are formed on the surface by sputtering, and a laser heat treatment is used in an oxidizing atmosphere.

Abstract: Method of masking one or more extremities of a cylinder bore from internal thermal spraying, when using a rotary gun inserted from one end of the bore, by essentially the steps of: (a) supporting one or more inflatable mask members adjacent an end of the bore wall; (b) pressurizing the inflatable mask member to expand and annularly engage an end of the bore, the mask being constituted of an inflatable and collapsible air tight bag of heat resistant (fiberglass) cloth coated on opposite sides with a sacrificial heat resistant non-stick coating (silicone). The inflatable characteristic of the mask member allows it to conform to the periphery of the cylinder bore extremities, and allows it to be easily installed in or through the component in its deflated condition. The mask is reusable by being comprised of coating material that may gradually be sacrificed to heat and wear of the over spray.

Abstract: A masking tape for use in masking a part in a high velocity oxy-fuel (HVOF) plasma spray process. The tape is formed from a fabric which is tightly woven from yarns of aramid fibers. A silicone rubber impregnates the inner fabric layer. First and second silicone rubber layers are coated onto opposite sides of the impregnated fabric. A first silicone pressure-sensitive adhesive, which is a rare metal cured adhesive, is coated onto the second silicone rubber layer. A second silicone pressure-sensitive adhesive is coated onto the first silicone pressure-sensitive adhesive. A release liner is preferably laminated to the second pressure-sensitive adhesive.

Abstract: A method and apparatus for increasing blade fatigue strength in a turbine engine. The blades in the turbine engine are configured so as to reduce stress at the tip of the blades during operation of the turbine engine, thus increasing blade fatigue strength. This stress reduction helps to counteract the detrimental effect of abrasive tip coatings on blade fatigue strength. In one embodiment, the tip of the blade is chamfered in order to reduce the stress on the tip of the blade. An abrasive coating is then applied to the tip of the blade to assist the blade in seating into an abradable outer air seal. In another embodiment, an abrasive coating is applied to a center portion of the tip of the blade, with the periphery of the abrasive coating being set back from the opposing surfaces of the blade.

Abstract: A method of manufacturing composite magnetic component comprising: a magnetic member or a magnetic base member made of a magnetic material; and a non-magnetic region as a modified magnetic property section being provided in a portion of said magnetic member or magnetic base member in the entire thickness thereof and having a magnetic property modified though composition modified by means of irradiation of an energy beam.

Abstract: A journal bearing assembly includes a steel bearing body and a Babbitt metal liner which defines an internal bearing surface and provides a sliding bearing for a rotating journal. A porous metal bonding layer of NiAl 80/20 or AlSi 12 is applied between the bearing body and the liner. The bonding layer is spray deposited onto the bearing body and the liner is spray deposited onto the bonding layer. The liner is most porous at the bonding layer interface with decreasing porosity toward the bearing surface. The bonding layer may be flame sprayed or applied in powder form and fused. Similarly, the liner may be flame sprayed or applied in powder form and fused.

Abstract: A metallized epoxy die formed by depositing boron nitride and iron oxide particle layers on the pattern used to form the die and spraying molten metal onto the particle layers followed by casting the epoxy against the exposed surface of the sprayed metal.

Abstract: A discharge element comprises a linear electrode and a sheet electrode both of which are provided opposite to each other with an insulator sheet therebetween, in which the linear electrode is formed by plasma spray coating a high-meting point semiconductor so as not to be worn when a high-frequency high voltage is applied between both electrodes.

Abstract: Oxygen sensor for air-fuel ratio control is provided with a sensor element having an oxygen ion-conductive main body and electrodes on both sides thereof, and at least one porous protective layer covering the electrode on the exhaust gas side. The protective layer includes an oxygen storage component OSC without copresence of a noble metal catalyst. The protective layer is intermeshingly connected to the main body via spherical protrusions of the main body. Double-layered protective layer structure includes OSC noncontaining layer (optionally containing catalyst) and OSC containing layer, as inner and outer protective layer or vice versa. OSC containing layer is formed by impregnation with OSC-solution through immersing the respective porous protective layer, or by cosintering the OSC containing green coating layer. By impregnation 0.2-8 wt %, or by cosintering 0.2-30 wt %, of OSC metal element is containable. The outer protective layer is thinner and more porous than the inner protective layer.

Abstract: A process for producing electrically conductive surfaces on infrared emitting military targets, wherein the electrically conductive surfaces, when electrified, heat up and produce an infrared image on the face of the target, where the process accommodates imperfections inherent in the structural components of the target, said target being substantially constructed of relatively inexpensive coarse materials, such as strand board; wherein the process consists of building up pattern designs of multiple thin layers of an arc-sprayed zinc having an unusually high resistivity, until the pattern designs attain a resistance and wattage that will have a uniform desired surface temperature throughout the pattern design, said design producing a realistic signature infrared image.

Abstract: A single pass, multiple target, continuous sputtering process for manufacturing photomask blanks comprising a single masking layer having plural strata of different composition and gradual compositional transitions between strata. Photomask blanks are useful in the process of integrated circuit manufacture.

Abstract: A method of forming high temperature resistant coatings having magnetic particles in a ceramic matrix by plasma spraying. Typically, the surface to be coated is cleaned by a combination of solvent cleaning and abrasion, such as by grit blasting. A mixture of ceramic particles and metal particles is provided and the mixture is plasma sprayed onto the surface using a sufficiently large proportion of metal particles to form a conductive first coating layer. A second layer is plasma sprayed with a mixture having a gradually decreasing metal particle content. A third layer is plasma sprayed using a mixture having a sufficiently low proportion of metal particles as to be dielectric. A pattern of small, spaced, conductive areas is then formed on the surface of the third layer. The resulting coating is durable, high temperature resistant and absorbs incident microwave energy.