Abstract: A method for reducing oxygen content in metal coatings deposited by gas stabilized plasma spray techniques comprises the following steps. A metal powder is provided. Carbon is adhered and coated to the metal powder and a carbon coated metal powder is formed. A primary gas is provided to a plasma spray gun at a flow rate in the range of about 30-80 liter/min. A carrier gas is also provided to the plasma spray gun at a flow rate in the range of about 4-8 liter/min. The carbon coated metal powder is provided to the plasma gun at a flow rate in the range of about 30-85 gms/min. The plasma spray gun is positioned at a stand-off distance in the range of about 100-175 mm from a substrate. The plasma spray gun is energized with power in the range of about 28-42 kW. The carbon coated metal powder is sprayed onto the substrate and a metal coating having an oxygen content at least 20% by weight less than an oxygen content of the metal powder, is deposited.

Abstract: A composite coating (1) resistant to wear is applied onto a substrate (2) and contains a mixture of hard material particles (3) and particles (5) of a solid lubricant (6). The particles (3, 5) are incorporated in a binder alloy (4). The lubricant particles are each enclosed by a protective envelope (7). The protective envelope substantially prevents bonding between components of the lubricant (6) on the one hand and components of the binder alloy (4) as well as of the hard material particles (3) on the other hand.

Abstract: A method of repairing an oxide-based refractory body by projecting a powder mixture against a hot surface of the body and in the presence of oxygen to provide a refractory repair mass includes providing a powder mixture composed of particles of at least one refractory oxide; fuel particles which react in an exothermic manner with the oxygen to form a refractory oxide and which are particles composed of at least one element selected from the group consisting of magnesium, aluminum, silicon, and mixtures thereof; and particles of silicon carbide present in an amount which is effective to provide a reduced porosity of the refractory repair mass and which does not exceed 10% by weight based on the weight of the powder mixture; and projecting the powder mixture against a hot surface of the oxide-based refractory body and in the presence of oxygen. Preferably, the powder mixture contains at least 1%, most preferably from 1 to 5%, by weight of the particles of silicon carbide.

Abstract: A method for lubricating glass contacting surfaces of glass forming equipment is disclosed. The method comprises the steps of delivering MAPD gas to a venturi at a low pressure, preferably below 10 p.s.i., and delivering oxygen to the venturi at a lower pressure, usually is half or less than half of the pressure at which the MAPD gas is delivered to the venturi. The MAPD gas and the oxygen are mixed in the venturi and delivered to and through a nozzle which is directed toward a glass contacting surface. The mixture is ignited as it leaves the nozzle; its flow is controlled so that the temperature of the flame is between approximately 1500 and 1800 degrees K. By controlling the temperature of the flame, the method is operable to deposit on the glass contacting surface a lubricating coating of graphite including a substantial percentage of flat plate graphite.

Abstract: This invention is directed to the creation of diamond coatings with enhanced adherence, nucleation density and uniformity on substrates. The method of this invention includes the formation of a carbide layer on a substrate surface prior to diamond coating deposition via a pretreatment stage using an unmodified oxy-acetylene combustion flame. The carbide layer may be formed at a temperature outside of the normal deposition temperature range and is treated as a separate step in the diamond growth process. The carbide layer serves to improve nucleation density, uniformity and adherence of the subsequent diamond coating. Many different types of substrates may benefit from the advantages of this invention.

Abstract: A method for applying coatings to substrates using combustion chemical vapor deposition by mixing together a reagent and a carrier solution to form a reagent mixture, igniting the reagent mixture to create a flame, or flowing the reagent mixture through a plasma torch, in which the reagent is at least partially vaporized into a vapor phase, and contacting the vapor phase of the reagent to a substrate resulting in the deposition, at least in part from the vapor phase, of a coating of the reagent which can be controlled so as to have a preferred orientation on the substrate, and an apparatus to accomplish this method.

Abstract: A thermal spray process for producing a MCrAlY-based coating wherein M is selected from the group consisting of iron, cobalt, nickel and mixtures thereof and wherein the carbon in the fuel of the thermal spray process converts between 30 to 80 percent by weight of the chromium component in the coating to chromium carbide.

Abstract: A hardfacing for downhole progressing cavity pumps is disclosed as well as a method for producing same. The hardfacing consists of a metal carbide layer applied to the ferrous pump rotor body by way of plasma spraying and a top layer of metallic material having a lower hardness than the metal carbide. The metal carbide layer has a grainy surface with a plurality of peaks and intermediate depressions, the peaks being formed by metal carbide grains at the surface of the metal carbide layer. The thickness of the top layer is adjusted such that the depressions between the peaks of the metal carbide layer are completely filled thereby providing the rotor with a metal carbide hardfacing of significantly reduced surface roughness. In the process of the invention, the pump rotor, which may be provided with a molybdenum bonding layer, is plasma coated with the metal carbide and the resulting carbide layer is covered with the metallic material top layer.

Abstract: A method and composition for the deposition of a thick layer (10) of diamond or diamond-like material. The method includes high temperature processing wherein a selected composition (12) including at least glassy carbon is heated in a direct current plasma arc device to a selected temperature above the softening point, in an inert atmosphere, and is propelled to quickly quenched on a selected substrate (20). The softened or molten composition (18) crystallizes on the substrate (20) to form a thick deposition layer (10) comprising at least a diamond or diamond-like material. The selected composition (12) includes at least glassy carbon as a primary constituent (14) and may include at least one secondary constituent (16). Preferably, the secondary constituents (16) are selected from the group consisting of at least diamond powder, boron carbide (B.sub.4 C) powder and mixtures thereof.

Abstract: A method for forming a hardened coating on a workpiece, such as a corrugating roll, having an undulated surface. A high velocity oxygen fueled gun is aligned with the undulated surface and a coating material is sprayed onto the surface from the gun to form a hardened coating having substantially uniform surface characteristics. The coating material is a tungsten carbide-cobalt material, or other hard carbide or oxide materials, which is sprayed onto the surface in a direction which is parallel to and offset from a plane passing through the longitudinal center of the roll. During the spraying operation, the gun is traversed along the length of the roll while the roll is rotated.

Abstract: A layer of material is thermally sprayed onto a portion of the surface of a vehicle wheel rim drop well with an arc plasma spray gun. Before spraying, the drop well surface is prepared by removing any dirt, oil and oxides. The sprayed layer has a greater density than the metal forming the wheel rim and reduces the porosity of the drop well.

Abstract: A working electrode or an electrochemical-enzymatic sensor system has a metallic base body which is provided with a thin layer of amorphous hydrogenated carbon (a-C:H).

Abstract: The oxidation protection for a surface of a carbon/carbon composite substrate having a primary protective coating previously formed thereon is improved by applying to said surface a layer of a coating material comprising titanium diboride, colloidal silica, and an intermetallic compound, e.g., silicon carbide. The primary coating can be a boronated silicon carbide coating.

Abstract: A composite metallizing wire useful in thermal flame spraying, having a conductive metallic solid core wire strand and a coating consisting of solid lubricant particles (i.e., graphite, BN, Teflon) and wear-resistant particles (i.e., SiC, TiC, Cr.sub.3 C.sub.2) homogeneously suspended in a conductive metal (i.e., Ni, Fe, Cr, Mo, Ti) complementary to said solid core wire strand. The wire is used to produce a metal matrix composite coating, comprising providing a thermalizing through-flow chamber with an exit nozzle, the chamber having a gas flow-through of at least 100 ms.sup.-1, establishing a flame in said chamber, and feeding a composite coated wire into said flame to be melted and projected by the gas flow to a target, the wire being constructed as above.

Abstract: A novel apparatus and method for the cyclic growth-etch deposition of diamond on a substrate by flame chemical vapor deposition (CVD) is developed. The cyclic growth-etch diamond deposition is accomplished by placing a suitable substrate to be coated under a CVD flame and providing a disk or face plate or other shapes having one or more teeth (or holes) wherein upon rotation of the disk, or face plate, or other shape, the teeth attached to the disk, or face plate, or other shape obstruct the path of the CVD flame from contacting the substrate at a desired time scale of .tau..sub.growth and t.sub.cycle to produce high quality (FWHM of 1-3.5 cm.sup.-1) diamond.

Abstract: A dart barrel having a surface coating applied thereto that provides the dart barrel with an increased resistance to wear and an increased coefficient of friction. The surface coating is sprayed onto the dart barrel in a semi-molten form. The dart barrel is then heat processed wherein the dart barrel is heated and the material of the surface coating and material of the dart barrel diffuse into each other bonding the two materials together.

Abstract: A particle of an inorganic or metallic material which is coated on the surface with ultrafines of an inorganic or metallic material. The coated particle is produced by introducing the particles of the inorganic or metallic material to be coated into a stream carrying the ultrafines of the inorganic or metallic material formed in a vapor phase and bringing the particles to be coated into contact with said ultrafines in a fluidized state. The coated particles are used for the production of a sintered product.

Abstract: Molybdenum disilicide base materials and methods for producing them are described. Mixtures of MoSi.sub.2 powder and other powders including SiO.sub.2, Si.sub.3 N.sub.4, SiC and Mo.sub.5 Si.sub.3 are plasma sprayed. Another embodiment which involves oxidation of MoSi.sub.2 is also disclosed. The resistant materials have particular utility as coatings for Nb alloys.

Abstract: The surface of titanium is treated to reduce the friction coefficient and wear loss without sacrificing its corrosion resistance. Pure titanium or titanium alloy is subjected to plasma-carburizing in an atmosphere containing hydrocarbon gas at a pressure of 0.5 to 15 Torr and a temperature of 700.degree. to 1100.degree. C.

Abstract: Broadly, the present invention is directed to improving a chemical vapor phase deposition (CVD) method for synthesis of diamond wherein a hydrocarbon/hydrogen gaseous mixture is subjected to a combustion flame in the presence of oxygen to at least partially decompose the gaseous mixture to form CVD diamond. The improvement in process comprises subjecting said combustion flame to one or more of dielectric heating, d.c. discharge, or a.c. discharge. Dielectric heating can be accomplished by subjecting the combustion flame to microwave (MW) frequency discharge or radiofrequency (RF) discharge. By superimposing dielectric heating or d.c./a.c. discharge plasma generation on combustion flame process, the carbon utilization rate of the combustion flame process should improve substantially.

Abstract: A process for forming a hard surface coating on titanium alloys includes providing a piece of material containing titanium having at least a portion of one surface to be hardened. The piece having a portion of a surface to be hardened is contacted on the backside by a suitable heat sink such that the melting depth of said surface to be hardened may be controlled. A hardening material is then deposited as a slurry. Alternate methods of deposition include flame, arc, or plasma spraying, electrodeposition, vapor deposition, or any other deposition method known by those skilled in the art. The surface to be hardened is then selectively melted to the desired depth, dependent on the desired coating thickness, such that a molten pool is formed of the piece surface and the deposited hardening material. Upon cooling a hardened surface is formed.

Abstract: A process for depositing a diamond coating on a substrate at temperatures less than about 550.degree. C. A powder mixture of glassy carbon and diamond particles is passed through a high velocity oxy-flame apparatus whereupon the powders are heated prior to impingement at high velocity against the substrate. The powder mixture contains between 5 and 50 powder volume percent of the diamond particles, and preferably between 5 and 15 powder volume percent. The particles have a size from about 5 to about 100 micrometers, with the diamond particles being about 5 to about 30 micrometers. The flame of the apparatus provides a velocity of about 350 to about 1000 meters per second, with the result that upon impingement upon the substrate, the glassy carbon is phase transformed to diamond as coaxed by the diamond content of the powder mixture.

Abstract: A tabular diamond crystal is formed on a substrate by gas phase synthesis, wherein the diamond crystal has a ratio of thickness to width of from 1:4 to 1:1,000 and the surface of the substrate on which the diamond crystal has been formed and the top surface of the diamond crystal are at an angle ranging from 0.degree. to 10.degree..

Abstract: This invention is directed to the creation of diamond coatings with enhanced adherence on substrates, such as tungsten carbide-cobalt (WC-Co), by chemical vapor deposition. This process comprises the steps of creating a combustion flame, supplying a deposition promoter to the flame, positioning a substrate into the flame, and forming the diamond deposit with enhanced adherence on the substrate. The invention is also directed to methods for the formation of a diamond deposit with enhanced adherence by the addition of a high-temperature binder such as a refractory metal or an organometallic compound. Once incorporated, the high-temperature binder acts as a cement which increase the strength and adhesion of the coating to the substrate.

Abstract: A chemical vapor deposition (CVD) technique (process and apparatus) for the growth of diamond films using vapor mixtures of selected compounds having desired moieties, specifically precursors that provide carbon and etchant species that remove graphite disclosed. The selected compounds are reacted in a plasma created by a confined rf discharge to produce diamond films on a diamond or a non-diamond substrate. In a preferred embodiment a gas phase mixture including at least 20% water which provides the etchant species is reacted with an alcohol which provides the requisite carbon precursor at low temperature (300.degree.-650.degree. C.) and low pressure (0.1 to 10 Torr), preferably in the presence of an organic acid (acetic acid) which contributes etchant species reactant. In the preferred embodiment the volumetric mixtures have typically been 40-80% water and 60-20% alcohol. The gaseous mixture of H.sub.2 O and alcohol is dissociated to produce H, OH, and carbon radicals.

Abstract: A method of forming crystalline silicon carbide films is disclosed. The method comprises a chemical vapor deposition process in which a substrate is heated to a temperature above about 600.degree. C. in the presence of a silicon containing cyclobutane gas.

Abstract: A manufacturing method for immersion members for molten metal baths, wherein a thermal sprayed coating including 1-50 wt % of tungsten boride, 3-25 wt % of one or more of Ni, Co, Cr, and Mo as a metal phase, and a remainder including tungsten carbide, is formed on the surface of a immersion member for use in molten metal baths, and subsequently, impregnation processing is conducted with respect to the thermal sprayed coating in a processing fluid having as a main component thereof chromic acid (H.sub.2 CrO.sub.4 and H.sub.2 Cr.sub.2 O.sub.7), and subsequently, baking processing is conducted. In accordance with this manufacturing method, a surface layer possessing fine microstructure and high bond strength not conventionally available is provided, and it is possible to manufacture a superior immersion member for use in molten metal baths which has superior resistance to corrosion, resistance to corrosive peeling, and resistance to abrasion, and to which metals do not easily adhere.

Abstract: An apparatus (10) for applying a thermal spray coating onto a substrate (24) includes a chamber (16) having an open bottom portion (18), a gas source for releasing a gas lighter than oxygen into the chamber (16) and displacing the oxygen from the chamber (16), and a spray gun (30) for spraying coating through the gas in the chamber (16) and onto the substrate (24).A method is also provided including the steps of displacing oxygen from the chamber (16) with the gas, and spraying the coating through the gas and onto the substrate (24) disposed within the chamber, the gas preventing oxidation between the substrate (24) and layers of the coating.

Abstract: A method for vapor deposition of diamond by effecting an arc discharge while feeding a discharge gas between an anode and a cathode of a thermal plasma chemical vapor deposition device, radicalizing a gaseous carbon compound by feeding the gaseous carbon compound into a generated plasma jet, and permitting the radicalized plasma jet to impinge on a substrate to be treated, whereby a film of diamond is formed on the substrate.

Abstract: A method of thermally spraying a solid lubricant (i.e. graphite or BN) impregnated metal matrix onto a metal target, using the steps of: (a) creating a flame or arc into which a consummable strand is fed, the strand being constituted as a hollow sheath of metal and a core therein comprising essentially solid lubricant powder particles, the flame or arc melting the metal of such strand; (b) applying a pressurized jet of atomizing gas to the melt and included graphite particles to project a spray of molten heavy metal and graphite particles generally homogeneously distributed throughout such spray, said graphite being protected against ablation during transit from the flame or arc to the target; and (c) surface heat treating essentially only the deposit to precipitate additional graphite while densifying the metal and controlling microstructure.

Abstract: A method of making an anti-friction coating on a metal surface subject to sliding wear, including the steps of: forming an encapsulated powder having grains made of a core of solid lubricants including at least graphite and MoS.sub.2 (others may include BN, NaF, LiF, CaF.sub.2, and WS.sub.2), and a thin shell of fusable soft metal such as Ni, Co, Fe, Zn, Sn, Mg, or Cu; plasma spraying the powder onto a light metal surface, such as a cylinder bore wall of an internal combustion engine, to form a coating; and finish-smoothing the coating to a uniform thickness of about 25-175 microns. Some core particles may be hard, wear-resistant particles such as SiC, NiCrAl, FeMn, FeCrAl, FeWNiVCr, NiCrMoVW, FeCrMoWV, CoFeNiCrMoWV, NiCrMoV, and CoMoCrVW.

Abstract: Drill bits having projecting inserts are completely coated with refractory material including on the edge margins about the inserts by thermally spraying with refractory particles whose particulate constituent under the spraying conditions is able to penetrate the inserts. Completely coated drill bits are provided.

Abstract: A process for forming a diamond gas phase synthesized coating film which is easily controlled and affords a high quality, good adhesion strength diamond film includes a step of forming a mixed layer of a plasma spraying material and diamond by simultaneously conducting plasma injection by a plasma spraying, a first torch and plasma CVD by a CVD plasma, second torch to thereby form a mixed layer on the substrate. The first and second torches are structurally distinct and have respective, separately and selectively controlled plasma generation operating conditions.

Abstract: A method of operation of a plasma torch, an internal burner or the like to produce a hot gas jet stream directed toward a workpiece to be coated by operating the plasma torch or internal burner at high pressure while feeding a powdered material to the stream to be heated by the stream and projected at high velocity onto a workpiece surface.

Abstract: A carbon film consisting of diamond powder contains nitrogen and boron therein. In the light of the addition of nitrogen and boron, the diamond is fabricated without growing defects and the film make in sturdy mechanical contact with the underlying surface.

Abstract: A method for forming an abradable composite material and the material so formed. A filler is fed axially into a stream of high-temperature combustion gases such that the filler is entrained in the gaseous stream. The gaseous stream containing the filler is then used to atomize the molten tip of a metal wire which is continuously fed into the gaseous stream. The resultant gaseous stream which contains both the filler and the atomized molten metal is directed to the surface of a target. The filler and the molten metal impact the target and combine to form a substantially continuous metal matrix in which the interstices are filled by the filler. The composite material abrades readily upon frictional contact with a moving part.

Abstract: A process is disclosed for forming a coating on a substrate. A metal layer is placed onto the substrate either by plasma spray deposition or by applying a metal foil and then subjecting it to rapid omnidirectional compaction. The metal is then reacted with a source of carbon, nitrogen, or a combination thereof, such that a metal carbide, nitride, or carbonitride layer is formed. The product is a densified coated ceramic composition.

Abstract: A method is disclosed for spray coating material which employs a plasma gun that has a cathode, an anode, an arc gas inlet, a first powder injection port, and a second powder injection port. A suitable arc gas is introduced through the arc gas inlet, and ionization of the arc gas between the cathode and the anode forms a plasma. The plasma is directed to emenate from an open-ended chamber defined by the boundary of the anode. A coating is deposited upon a base metal part by suspending a binder powder within a carrier gas that is fed into the plasma through the first powder injection port; a material subject to degradation by high temperature oxygen reactions is suspended within a carrier gas that is fed into the plasma through the second injection port. The material fed through the second injection port experiences a cooler portion of the plasma and has a shorter dwell time within the plasma to minimize high temperature oxygen reactions.

Abstract: A process and apparatus for producing a diamond film from a gas phase, in which a fuel gas is burnt by oxygen gas in a torch, to thereby provide a gas flame jet having a high temperature and high speed sufficient to form a high quality diamond film on a substrate, by an unlimited use of various kinds of combustible carbon compound gases as the fuel gas. A process and apparatus for producing a diamond film from a gas phase, in which a thermal spray material is fed to a combustion flame to thereby form an intermediate layer of a mixture of the thermal spray material and diamond between a substrate and a diamond film, to thereby provide a high purity diamond film having an improved adhesion to the substrate.

Abstract: When a mixture of gases containing carbon is burned to form a film of diamond on a surface of a substrate held at an appropriate temperature, it is so burned as to form a substantially flat region of incomplete combustion lying in parallel to the substrate surface and contacting it, while the region is surrounded by an air-shielding gas stream or formed under a reduced pressure.

Abstract: A diamond film of the vapor phase process is produced by a method which comprises a step of (1) electrolytically polishing the surface of a hard metal substrate with a pulse voltage or, after electrolytic polishing, further subjecting it to a scratching treatment with an abrasive powder or (2) electrolytically polishing the surface of a hard metal substrate with a constant voltage and thereafter subjecting it to a scratching treatment with an abrasive powder, thereby heightening the adhesive force of the surface of the substrate, and then effecting deposition of dense diamond of high adhesive strength by the vapor phase process on the substrate.

Abstract: A light transmitting, absorbing coating is produced on a substrate by depositing by cathode sputtering alternate layers of silicon in an oxidizing residual gas atmosphere and chrome in a non-oxidizing residual gas atmosphere. The light transmitting layer comprises a substrate having a coating of a bluish-grey transmission color which comprises a plurality of alternate chrome and silicon dioxide layers with the thickness of the individual chrome layers being smaller than 10 nm.