Additionally Containing Nickel, Cobalt, Or Iron As Free Metal Or Alloy Patents (Class 427/451)
  • Patent number: 10975255
    Abstract: A coating including one or more nano-materials and an organic material, the one or more nano-materials being present in a concentration of up to about 30% by weight, based on the total weight of the coating. A razor including one or more blades and a coating disposed on at least one of the one or more blades. The coating on the one or more blades of the razor including one or more nano-materials and an organic material, the one or more nano-materials being present in a concentration of up to about 30% by weight, based on the total weight of the coating.
    Type: Grant
    Filed: October 25, 2018
    Date of Patent: April 13, 2021
    Assignee: BIC-VIOLEX S.A.
    Inventors: Gerasimos Vasileiou, Georgios Vlachos, Vasileios Papachristos, John Parthenios, Konstantinos Papagelis
  • Patent number: 10596628
    Abstract: Embodiments described herein relate generally to systems and methods for using nanocrystalline metal alloy particles or powders to create nanocrystalline and/or microcrystalline metal alloy articles using additive manufacturing. In some embodiments, a manufacturing method for creating articles includes disposing a plurality of nanocrystalline particles and selectively binding the particles together to form the article. In some embodiments, the nanocrystalline particles can be sintered to bind the particles together. In some embodiments, the plurality of nanocrystalline particles can be disposed on a substrate and sintered to form the article. The substrate can be a base or a prior layer of bound particles. In some embodiments, the nanocrystalline particles can be selectively bound together (e.g., sintered) at substantially the same time as they are disposed on the substrate.
    Type: Grant
    Filed: March 3, 2017
    Date of Patent: March 24, 2020
    Assignee: Veloxint Corporation
    Inventors: Alan C. Lund, Christopher A. Schuh
  • Patent number: 10287526
    Abstract: A nanocomposite coating and method of making and using the coating. The nanocomposite coating is disposed on a base material, such as a metal or ceramic; and the nanocomposite consists essentially of a matrix of an alloy selected from the group of Cu, Ni, Pd, Pt and Re which are catalytically active for cracking of carbon bonds in oils and greases and a grain structure selected from the group of borides, carbides and nitrides.
    Type: Grant
    Filed: December 18, 2017
    Date of Patent: May 14, 2019
    Assignee: UChicago Argonne, LLC
    Inventors: Ali Erdemir, Osman Levent Eryilmaz, Mustafa Urgen, Kursat Kazmanli
  • Patent number: 9845441
    Abstract: A nanocomposite coating and method of making and using the coating. The nanocomposite coating is disposed on a base material, such as a metal or ceramic; and the nanocomposite consists essentially of a matrix of an alloy selected from the group of Cu, Ni, Pd, Pt and Re which are catalytically active for cracking of carbon bonds in oils and greases and a grain structure selected from the group of borides, carbides and nitrides.
    Type: Grant
    Filed: February 1, 2016
    Date of Patent: December 19, 2017
    Assignee: UChicago Argonne, LLC
    Inventors: Ali Erdemir, Osman Levent Eryilmaz, Mustafa Urgen, Kursat Kazmanli
  • Patent number: 9776246
    Abstract: A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.
    Type: Grant
    Filed: November 25, 2014
    Date of Patent: October 3, 2017
    Assignee: Howmedica Osteonics Corp.
    Inventors: Daniel E. Lawrynowicz, Aiguo Wang, Zongtao Zhang, Haitong Zeng
  • Patent number: 9650585
    Abstract: A solid lubricant magnetron sputtering physical vapor deposition (MS PVD) coating can be used e.g. in automotive, aircraft and space industries for increasing lifetime of moving parts such as bearings, chains, pistons and joints that experience sliding or rolling friction. A nanocomposite solid lubricant coating contains a carbon matrix with copper grains and at least one of Ti, Zr, Hf, and V, in bulk proportions, at. %: carbon ?5-35; copper 50-90; additional metal ?5-15. The carbon matrix with copper grains is reinforced with interlayers of the additional metal. The thickness of each layer of the carbon matrix with copper grains is in the range between 30 and 150 nanometers and the thickness of each interlayer of the additional metal is in the range between 5 and 20 nanometers. The hardness of said coating is in the range between 200 and 1000 HV.
    Type: Grant
    Filed: August 11, 2015
    Date of Patent: May 16, 2017
    Assignee: NACO TECHNOLOGIES, SIA
    Inventors: Pavels Nazarovs, Valery Mitin, Vladimirs Kovalenko
  • Publication number: 20150069020
    Abstract: A contact element for high voltage direct current switches includes a matrix made of a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold, and alloys thereof. The contact element also includes a foreign phase, which is dispersed in the matrix and is made of a second material selected from the group comprising carbon, tin(II) oxide, tin(IV) oxide, zinc(II) oxide, tungsten, nickel and mixtures thereof. The contact element has a porosity of ?1.0% by volume, based on a total volume of the contact element.
    Type: Application
    Filed: September 10, 2014
    Publication date: March 12, 2015
    Inventors: Juergen STEINWANDEL, Dietrich JONKE, Helmut PIRINGER
  • Publication number: 20150054223
    Abstract: This invention relates to thermal spray coatings, powders useful in deposition of the thermal spray coatings, methods of producing the powders, and uses of the thermal spray coatings, for example, coating of piston rings and cylinder liners of internal combustion engines. The coatings of this invention are applied by thermal spray deposition of a powder. The powder contains bimetallic carbides of chromium and molybdenum dispersed in a matrix metal. The matrix metal contains nickel/chromium/molybdenum.
    Type: Application
    Filed: October 30, 2014
    Publication date: February 26, 2015
    Inventors: WILLIAM JOHN CRIM JAROSINSKI, VLADIMIR BELOV
  • Patent number: 8927111
    Abstract: There are provided a surface coating material for a molten zinc bath member with improved zinc corrosion resistance, a production method thereof, and a molten zinc bath member. The surface coating material comprises WC powder particles and a binder metal. The binder metal comprises Co and a metal element electrochemically nobler than Co and constitutes an alloy structure having a single phase.
    Type: Grant
    Filed: April 4, 2008
    Date of Patent: January 6, 2015
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Hiroki Ikeda, Katsu Yanagimoto
  • Patent number: 8877296
    Abstract: A method for producing a brake disc (BS) for a vehicle, with a main body (G) of a metal material, in particular gray cast iron, which has friction surfaces (R). The friction surfaces (R) are coated with a coating of tungsten carbide, chromium carbide, and nickel or of tungsten carbide, cobalt and nickel and after-treated by carbonizing, carbonitriding, case hardening, gas nitriding, oxide nitriding, gas nitro carburizing, plasma nitriding, plasma oxidizing, borating, plasma carborating or plasma borating.
    Type: Grant
    Filed: January 27, 2010
    Date of Patent: November 4, 2014
    Assignee: Daimler AG
    Inventors: Oliver Lembach, Ralph Mayer
  • Publication number: 20140234609
    Abstract: The invention relates to a thermal spray powder on a tungsten carbide basis, as well as to a method for the manufacture of such a spray powder for the thermal coating of a substrate, in particular for the thermal coating of a brake disc for a vehicle. In accordance with the invention, the spray powder includes, apart from impurities, WC in the range of 60% to 75% by weight, Cr3C2 in the range of 14% to 22% by weight and Ni in the range of 11% to 23% by weight. The invention further relates to a substrate, in particular for a brake disc having a thermal spray layer on a tungsten carbide basis, as well as to a method for the manufacture of a thermal spray layer on a substrate.
    Type: Application
    Filed: May 31, 2012
    Publication date: August 21, 2014
    Applicant: SULZER METCO WOKA GMBH
    Inventors: Guido Reisel, Manfred Oechsle
  • Publication number: 20140093378
    Abstract: A coating is described for an airfoil blade component. The coating comprises a cermet material and has, when applied to the rotor blade, a compressive residual stress greater than about 60 ksi. In another embodiment, the compressive residual stress of the coating is in the range of approximately 90-110 ksi.
    Type: Application
    Filed: October 2, 2012
    Publication date: April 3, 2014
    Inventors: Patrick Louis Clavette, Jun Shi, Aaron T. Nardi
  • Patent number: 8673402
    Abstract: The present disclosure relates to a method of spray cladding a wear plate. The method may include melting an alloy including glass forming chemistry, pouring the alloy through a nozzle to form an alloy stream, forming droplets of the alloy stream, and forming a coating of the alloy on a base metal. The base plate may exhibit a first hardness H1 of Rc 55 or less and the alloy coated base plate may exhibit a hardness H2, wherein H2>H1. In addition, the coating may exhibit nanscale or near-nanscale microstructural features in the range of 0.1 nm to 1,000 nm. Furthermore, the alloy coated base plate may exhibit a toughness of greater than 60 ft-lbs.
    Type: Grant
    Filed: November 10, 2008
    Date of Patent: March 18, 2014
    Assignee: The NanoSteel Company, Inc.
    Inventor: Daniel James Branagan
  • Patent number: 8609196
    Abstract: A wear- and corrosion-resistance coating over a metal substrate having a first-layer carbide material, a second metal coating layer over the first metal coating layer, and a surface metal coating layer over the second metal coating layer; and thermal spray method for applying the coating.
    Type: Grant
    Filed: May 28, 2010
    Date of Patent: December 17, 2013
    Assignee: Kennametal Inc.
    Inventors: David A. Lee, Heidi Lynette de Villiers-Lovelock, Danie Jacobus Dewet, James B. C. Wu
  • Publication number: 20130316086
    Abstract: A method of applying a wear-resistant coating comprises mixing about 75% to about 85% by weight chromium carbide and about 15% to about 25% by weight nickel chromium to form a chromium carbide-nickel chromium mixture, and simultaneously heating the chromium carbide-nickel chromium mixture to about 1371 degrees Celsius to about 2204 degrees Celsius and applying the chromium carbide-nickel chromium mixture at a velocity in a range of about 305 meters feet per second to about 915 meters per second by high velocity oxygen fuel (HVOF) spraying.
    Type: Application
    Filed: August 8, 2013
    Publication date: November 28, 2013
    Applicant: United Technologies Corporation
    Inventors: Eli N. Ross, Paul H. Zajchowski
  • Publication number: 20130266798
    Abstract: A method for protecting a work piece for use in abrasive environments with hardbanding is provided. The layer is deposited onto at least a portion of the work piece to be protected. The deposited layer exhibits a hardness of at least 50 Rc, a wear rate of less than 0.5 grams of mass loss as measured according to ASTM G65-04, Procedure A, a wear rate on a contacting secondary body comprising carbon steel of less than 0.005 grams as measured according to modified ASTM G77 wear test. The deposited alloy forms an iron matrix comprising embedded hard particles in an amount of less than 15 vol. %. The embedded hard particles have an average particle size of ranging from 100 nm to 5 ?m. In one embodiment, the deposition is via welding.
    Type: Application
    Filed: April 5, 2012
    Publication date: October 10, 2013
    Inventors: Justin Lee Cheney, Grzegorz Jan Kusinski, John Hamilton Madok
  • Publication number: 20130251910
    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).
    Type: Application
    Filed: May 16, 2013
    Publication date: September 26, 2013
    Inventors: Tetyana P. Shmyreva, James Knapp, Ardy Simon Kleyman
  • Patent number: 8541349
    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.
    Type: Grant
    Filed: September 20, 2007
    Date of Patent: September 24, 2013
    Assignee: Inframat Corporation
    Inventors: T. Danny Xiao, John Broadhead, Xinqing Ma
  • Patent number: 8535408
    Abstract: A hardmetal composition comprises tungsten carbide in an amount greater than 50 weight percent of the hardmetal composition. In addition, the hardmetal composition comprises a binder material consisting of at least 90 weight percent nickel, a binder flux between 3.5 to 10.0 weight percent chosen from the group consisting of boron and silicon, and less than 1.0 weight percent other components.
    Type: Grant
    Filed: January 24, 2012
    Date of Patent: September 17, 2013
    Assignee: Reedhycalog, L.P.
    Inventors: Jiinjen Albert Sue, Harold Sreshta, Rajagopala Pillai
  • Patent number: 8449950
    Abstract: A method and apparatus for forming an electrochemical layer of a thin film battery is provided. A precursor mixture comprising precursor particles dispersed in a carrying medium is activated in an activation chamber by application of an electric field to ionize at least a portion of the precursor mixture. The activated precursor mixture is then mixed with a combustible gas mixture to add thermal energy to the precursor particles, converting them to nanocrystals, which deposit on a substrate. A second precursor may be blended with the nanocrystals as they deposit on the surface to enhance adhesion and conductivity.
    Type: Grant
    Filed: August 24, 2010
    Date of Patent: May 28, 2013
    Assignee: Applied Materials, Inc.
    Inventors: Quanyuan Shang, Lu Yang, Karl M. Brown, Donald J. K. Olgado, Victor Pebenito, Hooman Bolandi, Tetsuya Ishikawa, Robert Z. Bachrach, Liang-Yuh Chen
  • Publication number: 20130020136
    Abstract: A hardmetal composition comprises tungsten carbide in an amount greater than 50 weight percent of the hardmetal composition. In addition, the hardmetal composition comprises a binder material consisting of at least 90 weight percent nickel, a binder flux between 3.5 to 10.0 weight percent chosen from the group consisting of boron and silicon, and less than 1.0 weight percent other components.
    Type: Application
    Filed: January 24, 2012
    Publication date: January 24, 2013
    Applicant: REEDHYCALOG, L.P.
    Inventors: Jiinjen Albert Sue, Harold Sreshta, Rajagopala Pillai
  • Publication number: 20120132106
    Abstract: A method for the coating of a substrate in which a starting material (P) is sprayed onto the substrate in the form of a process jet by means of plasma spraying, with the starting material (P) being injected into a plasma which defocuses the process jet and being melted partly or completely into a liquid phase there at a low process pressure which is at most 20,000 Pa, wherein a gas flow for the process jet is set such that the substrate is coated by deposition from the liquid phase in at least one region which is located in the geometric shadow with respect to the process jet.
    Type: Application
    Filed: May 7, 2010
    Publication date: May 31, 2012
    Inventors: Rajiv J. Damani, Malko Gindrat
  • Publication number: 20120126487
    Abstract: A sliding member for an internal combustion engine includes: a substrate and a coating obtainable by thermally spraying a powder, having the element proportions of 55 to 75 wt % of chromium, Cr; 3 to 10 wt % of silicon, Si; 18 to 35 wt % of nickel, Ni; 0.1 to 2 wt % of molybdenum, Mo; 0.1 to 3 wt % of carbon, C; 0.5 to 2 wt % of boron, B; and 0 to 3 wt % of iron, Fe.
    Type: Application
    Filed: April 15, 2010
    Publication date: May 24, 2012
    Inventors: Marcus Kennedy, Michael Zinnabold, Marc-Manuel Matz
  • Publication number: 20110305873
    Abstract: A coating composition includes a cermet material having metal carbide phase particles with an average size of less than 5 microns. The coating has an average surface roughness of less than approximately 5 microns. A system for applying a coating to a substrate includes a spray gun configured for use with a high velocity oxygen or high velocity air fuel system. The system further includes a cermet material supplied to the spray gun, wherein the cermet material includes at least approximately 34 percent by weight of a metal carbide phase having an average particle size of less than or equal to approximately 5 microns. The metal carbide phase is dispersed in a liquid selected from the group consisting of water, alcohol, an organic combustible liquid, or an organic incombustible liquid.
    Type: Application
    Filed: June 9, 2010
    Publication date: December 15, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Tamara Jean Muth, James Anthony Ruud, Leonardo Ajdelsztajn, Prajina Bhattacharya
  • Patent number: 8066795
    Abstract: A thermal spray powder including cermet particles, each of which contains metal containing at least one selected from the group consisting of cobalt, chrome, and nickel, and tungsten carbide. The ratio of the summed weight of cermet particles having a particle size of 25 ?m or more in the thermal spray powder with respect to the summed weight of the entire cermet particles in the thermal spray powder is 0.5 to 15%. A thermal spray coating formed from the thermal spray powder is suitable for the formation of a tungsten carbide-based cermet thermal spray coating for use in rolls such as corrugated rolls.
    Type: Grant
    Filed: September 12, 2007
    Date of Patent: November 29, 2011
    Assignee: Fujimi Incorporated
    Inventors: Hiroaki Mizuno, Junya Kitamura
  • Patent number: 8067067
    Abstract: Disclosed herein is a method for applying plasma-resistant coatings for use in semiconductor processing apparatus. The coatings are applied over a substrate which typically comprises an aluminum alloy of the 2000 series or the 5000 through 7000 series. The coating typically comprises an oxide or a fluoride of Y, Sc, La, Ce, Eu, Dy, or the like, or yttrium-aluminum-garnet (YAG). The coating may further comprise about 20 volume % or less of Al2O3. The coatings are typically applied to a surface of an aluminum alloy substrate or an anodized aluminum alloy substrate using a technique selected from the group consisting of thermal/flame spraying, plasma spraying, sputtering, and chemical vapor deposition (CVD). To provide the desired corrosion resistance, it is necessary to place the coating in compression. This is accomplished by controlling deposition conditions during application of the coating.
    Type: Grant
    Filed: July 22, 2004
    Date of Patent: November 29, 2011
    Assignee: Applied Materials, Inc.
    Inventors: Jennifer Y. Sun, Senh Thach, Jim Dempster, Li Xu
  • Patent number: 7914856
    Abstract: The present invention provides methods for manufacturing an article having a wetting-resistant surface. The method includes providing a mixture comprising a plurality of micron-sized first particles and a plurality of nano-sized second particles, and a binder; depositing the mixture onto a substrate to form a wetting-resistant surface via a thermal spray process. The mixture is deposited without substantial melting of the first and second particles. The wetting-resistant surface has wettability sufficient to generate, with a reference fluid, a static contact angle of greater than about 90 degrees.
    Type: Grant
    Filed: June 29, 2007
    Date of Patent: March 29, 2011
    Assignee: General Electric Company
    Inventors: Tao Deng, Dennis Michael Gray, Todd Charles Curtis, Yuk-Chiu Lau, Dalong Zhong, Ming Feng Hsu, Nitin Bhate, Kripa Kiran Varanasi, Pazhayannur Ramanathan Subramanian, Margaret Louise Blohm
  • Publication number: 20110038780
    Abstract: Disclosed is a method for preparation of a nickel-carbonitride sphere, which includes preparing a melamine-formaldehyde resin, adding a nickel salt and a surfactant to the melamine-formaldehyde resin to prepare a nickel-melamine resin mixture, and conducting spray pyrolysis for the mixture to produce nickel-containing powder including nickel-carbonitride spheres. In addition, this method may further include thermal treatment of the nickel-containing powder.
    Type: Application
    Filed: June 25, 2010
    Publication date: February 17, 2011
    Applicant: KOREA ADVANCED INSTITUTE OF SCIENCE AND TECHNOLOGY
    Inventors: JEUNG-KU KANG, Se-Yun Kim, Jun-Ho Kwon, Seung-Jun Heo
  • Publication number: 20100316883
    Abstract: A wear- and corrosion-resistance coating over a metal substrate having a first-layer carbide material, a second metal coating layer over the first metal coating layer, and a surface metal coating layer over the second metal coating layer; and thermal spray method for applying the coating.
    Type: Application
    Filed: May 28, 2010
    Publication date: December 16, 2010
    Applicant: DELORO STELLITE HOLDINGS CORPORATION
    Inventors: David A. Lee, Heidi Lynette de Villiers-Lovelock, Danie Jacobus Dewet, James B. C. Wu
  • Patent number: 7851027
    Abstract: It is disclosed a method of depositing a seal coating and a seal system comprising at least two layers on the surface of an article. The upper or surface layer has a higher chromium activity than a bottom layer, to reduce a diffusion of cobalt and the formation of cobalt oxide is reduced. The coating of invention may be heat-treated to reduce or optimize the formation of cobalt oxide to sustain the wear property.
    Type: Grant
    Filed: October 7, 2008
    Date of Patent: December 14, 2010
    Assignee: Alstom Technology Ltd
    Inventors: Abdus Suttar Khan, Ian William Boston, James Alexander Hearley
  • Publication number: 20100304181
    Abstract: A coating composition is described, having a first coating layer which includes a nickel-chromium matrix in which metal carbide particles are dispersed; and a hard, dense second coating layer disposed over the first coating layer. The second coating layer is formed from a metal nitride-type material, and has an average roughness of less than about 80 micro-inches (Ra). Related articles and processes are also disclosed.
    Type: Application
    Filed: May 29, 2009
    Publication date: December 2, 2010
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Krishnamurthy Anand, Tamara Jean Muth, Srinidhi Sampath, Prajina Bhattacharya, Biju Dasan
  • Publication number: 20100279022
    Abstract: A process for providing a protective layer to an article. The process includes depositing a layer of material onto a surface of the article with a thermal spray process. Examples of thermal spray process include high velocity oxygen/air fuel, atmospheric plasma spray, and chemical vapor deposition. Coating methods, such as cold vapor deposition and physical vapor deposition, may also be used. The layer can then be bonded to the article by heating material in the layer adjacent its connection with the article.
    Type: Application
    Filed: May 4, 2009
    Publication date: November 4, 2010
    Applicant: Vetco Gray Inc.
    Inventors: Leonardo Ajdelsztajn, Dennis Gray, Fife B. Ellis, Joseph W. Pallini, JR.
  • Publication number: 20100239883
    Abstract: Described are methods of coating a polymer substrate including thermal coating substrate with a metallic boundary material to form a first layer and thermal coating the first layer with a metallic thermal spray material to form a second layer. Related coated articles, coated members, actuators and other items are also included.
    Type: Application
    Filed: February 9, 2010
    Publication date: September 23, 2010
    Applicant: Greene, Tweed of Delaware, Inc.
    Inventors: Steve Okladek, Kerry Drake, David Somerville
  • Publication number: 20100189910
    Abstract: A composite powder for a deposition of a composite coating comprises a nonmetallic component and a metallic component, the metallic component having an amorphous structure or a nanocrystalline structure. The metallic component may include an amorphous metallic alloy. The metallic alloy may include constituents having the amorphous structure. The metallic component may include a combination of the metallic alloy existing in the amorphous state and constituents of the amorphous metallic alloy in the amorphous state. The composite metal-ceramic powders are used for depositing composite coatings on a selected surface. Disclosed are several methods and systems for producing such composite powders. Disclosed are also several methods and systems for depositing composite coatings. Advantageously, the deposited coatings exhibit high corrosion resistance, high wear resistance, and excellent structural properties.
    Type: Application
    Filed: March 2, 2010
    Publication date: July 29, 2010
    Inventor: Vladimir E. BELASHCHENKO
  • Publication number: 20100127462
    Abstract: The present invention relates to a piston ring with improved running-in and wear behaviour as well as to a method for the production thereof. According to a first embodiment, the piston ring comprises a ring body (2), an adhesive promoter layer (4) of a Ni-alloy applied to the bearing surface of the ring body (2) by thermal spraying, a wear-resistant coating (6) of a Mo-alloy with CrC, WC, MoC applied to the adhesive promoter layer (4) by thermal spraying; and a running-in layer (8) of an AlCu-alloy or Ni-graphite-alloy applied to the wear-resistant coating (6) by thermal spraying. According to a second embodiment, the piston ring comprises a ring body, an adhesion layer applied to the bearing surface of the ring body, and a running-in layer, comprising nickel graphite, that is applied to the adhesion layer.
    Type: Application
    Filed: November 26, 2007
    Publication date: May 27, 2010
    Inventors: Michael Buchmann, Peter Schmidt, Marc-Manuel Matz, Johann Riedl
  • Publication number: 20100075133
    Abstract: There are provided a surface coating material for a molten zinc bath member with improved zinc corrosion resistance, a production method thereof, and a molten zinc bath member. The surface coating material comprises WC powder particles and a binder metal. The binder metal comprises Co and a metal element electrochemically nobler than Co and constitutes an alloy structure having a single phase.
    Type: Application
    Filed: April 4, 2008
    Publication date: March 25, 2010
    Applicant: SANYO SPECIAL STEEL CO., LTD.
    Inventors: Hiroki Ikeda, Katsu Yanagimoto
  • Publication number: 20100068405
    Abstract: A method of forming a wear resistant coating on a combustion turbine component includes melting an ingot including at least one metallic carbide to form a metallic liquid including at least one metallic carbide. The metallic liquid including at least one metallic carbide is atomized in an atmosphere to form a metallic powder including at least one metallic carbide. The metallic powder including at least one metallic carbide is milled to form a nanosized metallic powder including at least one metallic carbide. The nanosized metallic powder including at least one metallic carbide is thermally sprayed onto the combustion turbine component.
    Type: Application
    Filed: September 15, 2008
    Publication date: March 18, 2010
    Inventors: Sachin R. Shinde, Anand A. Kulkarni, Navin J. Manjooran
  • Publication number: 20100055339
    Abstract: A method is for forming a wear resistant coating on a workpiece. The method includes atomizing a metallic liquid including molybdenum in an atmosphere to form a crystalline metallic powder including molybdenum. The crystalline metallic powder is milled to form a nanocrystalline metallic powder including molybdenum. Moreover, the method includes thermal spraying the nanocrystalline metallic powder including molybdenum onto the workpiece.
    Type: Application
    Filed: August 26, 2008
    Publication date: March 4, 2010
    Inventors: Sachin R. Shinde, Anand A. Kulkarni
  • Publication number: 20090208662
    Abstract: A method for repairing a workpiece includes the steps of providing an unstripped, coated workpiece comprising a surface having a localized damage site; masking the workpiece about the localized damage site; generating a microplasma stream; and applying a first powdered material to the localized damage site using the microplasma stream; and applying a second powdered material to the workpiece surface using the microplasma stream. Another method for repairing a workpiece includes the steps of providing an unstripped, coated workpiece comprising a surface having a localized damage site; generating a microplasma stream; applying without a maskant a powdered metal alloy to the damage site using the microplasma stream; and dimensionally restoring the workpiece.
    Type: Application
    Filed: April 30, 2009
    Publication date: August 20, 2009
    Applicant: United Technologies Corporation
    Inventors: Donn R. Blankenship, Paul H. Zajchowski, Gary Shubert
  • Publication number: 20090155479
    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.
    Type: Application
    Filed: September 20, 2007
    Publication date: June 18, 2009
    Applicant: Inframat Corporation
    Inventors: T. Danny Xiao, John Broadhead, Xinqing Ma
  • Patent number: 7527832
    Abstract: A plasma spray process for structuring self-cleaning glass surfaces and self-cleaning glass surfaces formed according to the process. Molten or heat softened particles of inorganic material are plasma spray deposited onto the surface of a substrate to create a micro-rough surface. If desired, a hydrophobic top coating layer can optionally be applied to the micro-rough surface. The micro-structured surface formed according to the invention is durable and self-cleaning.
    Type: Grant
    Filed: April 27, 2005
    Date of Patent: May 5, 2009
    Assignee: Ferro Corporation
    Inventors: George E. Sakoske, Martin Baumann, Enos A. Axtell, III
  • Publication number: 20090053423
    Abstract: Improved coating blades are disclosed, as well as processes for manufacturing such blades. The inventive blades have an intermediate edge deposit effective to reduce heat transfer from a wear resistant top deposit to the blade substrate. In one embodiment, the intermediate layer is comprised of NiCr, possibly with embedded oxide particles. Suitably, the intermediate layer and the top deposit are applied by an HVOF process. It is also envisaged that the intermediate layer may be deposited by plasma spraying. The intermediate layer may comprise stabilized zirconia.
    Type: Application
    Filed: June 29, 2006
    Publication date: February 26, 2009
    Applicant: BTG ECLÉPENS S.A.
    Inventors: Silvano Freti, Jean Francois Laithier
  • Patent number: 7487840
    Abstract: The present disclosure provides a method, system, apparatus, and related alloy to provide a protective wear coating on a downhole component for a well through a synergistic use of a thermal spraying process in combination with a novel iron-based alloy. The thermal spraying process melts the material to be deposited while a pressurized air stream sprays the molten material onto the downhole component. The coating operation takes place at low temperatures without fusion or thermal deterioration to the base material. The wear resistance is increased while providing a lower coefficient of friction by the wear resistant layer relative to a coefficient of friction of the downhole equipment without the wear resistant layer. In at least one embodiment, the disclosed process using the iron-based alloy can apply a much thicker coating than heretofore has been able to be applied without spalling and without necessitating an intermediate buffer layer.
    Type: Grant
    Filed: April 28, 2005
    Date of Patent: February 10, 2009
    Assignee: Wear Sox, L.P.
    Inventors: John Hudson Gammage, Roger A. Daemen, Joe Lynn Scott
  • Publication number: 20080292897
    Abstract: A wear-resistant component of a carbon seal includes a surface and a coating applied onto the surface. The coating is a chromium carbide-nickel chromium composition constituting between about 75% and about 85% by weight chromium carbide and between about 15% and about 25% by weight nickel chromium. The chromium carbide-nickel chromium composition is applied onto the surface by high velocity oxy-fuel spraying (HVOF).
    Type: Application
    Filed: May 22, 2007
    Publication date: November 27, 2008
    Applicant: United Technologies Corporation
    Inventors: Eli N. Ross, Paul H. Zajchowski
  • Publication number: 20080199722
    Abstract: This invention relates to coatings for a metal or non-metal substrate comprising (i) a thermal sprayed bondcoat layer applied to said substrate comprising an alloy of MCrAlM? wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M? is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and wherein M comprises from about 35 to about 80 weight percent of said alloy, Cr comprises from about 15 to about 45 weight percent of said alloy, Al comprises from about 5 to about 30 weight percent of said alloy, and M? comprises from about 0.01 to about 1.0 weight percent of said alloy, said alloy thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns, said bondcoat having a surface roughness of at least 200 micro-inches, and said bondcoat having a thermal expansion of about 6.5 millimeters per meter or less between a temperature of from about 25° C. to about 525° C.
    Type: Application
    Filed: February 7, 2008
    Publication date: August 21, 2008
    Inventors: Prasad Shrikrishna Apte, James Patrick Meagher, Shawn W. Callahan
  • Publication number: 20080145555
    Abstract: The present invention provides a method for coating a substrate, in particular a fiber reinforced plastic component, a protective layer being applied, with preference by means of thermal spraying, to a non-cured resin film applied to a release film, and subsequently, after removal of the release film, the resin film being applied to the substrate and cured.
    Type: Application
    Filed: October 1, 2007
    Publication date: June 19, 2008
    Inventors: Rainer Kocik, Peter Knepper, Thomas Warda
  • Publication number: 20080072790
    Abstract: Methods of making a metallic or cerment coating include suspending solid fine metal or cerment particles in a liquid to form a liquid feedstock and injecting the liquid feedstock into an high-velocity oxygen fuel flame gun to thermally spray the liquid feedstock on a substrate to form a coating thereon.
    Type: Application
    Filed: September 20, 2007
    Publication date: March 27, 2008
    Applicant: Inframat Corporation
    Inventors: Xinqing Ma, Jeffrey Roth, T. Danny Xiao
  • Patent number: 7341533
    Abstract: A continuously variable transmission (CVT) includes an aluminum housing member having a bore formed therein. A rotatable pulley member is supported on a bearing within the bore. The bore includes a layer of thermal spray coating for improved wear resistance so that the bore supports the bearing without a steel sleeve therebetween.
    Type: Grant
    Filed: October 24, 2003
    Date of Patent: March 11, 2008
    Assignee: General Motors Corporation
    Inventors: Yucong Wang, Sime Stavreski, Jasbir Singh
  • Patent number: 7322099
    Abstract: A method for producing components for injection moulding comprising a body made of thermally conducting material with expansion coefficient matching that of the insulating layers and provided with a passage for the material to be injected. At least one strip of electrically conducting material with high change of resistance with temperature, forming a heating resistor or inductor is applied on a electrically insulating base layer previously directly applied on the body. At least one final insulating layer with low thermal emissivity is then applied to optimise electrical efficiency. The method utilises thermal spray techniques and can be applied also for production of other heating equipment.
    Type: Grant
    Filed: April 25, 2005
    Date of Patent: January 29, 2008
    Assignee: Inglass S.p.A.
    Inventors: Gianfranco Cirri, Maria Prudenziati
  • Publication number: 20070161318
    Abstract: A method of manufacturing a fluorescent lamp is provided. One of a dispersed metal oxide precursor sol prepared by a sol-gel reaction and a fluorescent substance slurry is coated on a glass tube having at least one open side and then the other of the fluorescent substance slurry and the dispersed metal oxide precursor sol is coated on the glass tube. Next, passivation and fluorescent layers are simultaneously formed by baking the coated layers. Then, air is exhausted out of the glass tube and a discharge gas is injected into the glass tube. Finally, the glass tube is sealed.
    Type: Application
    Filed: December 1, 2006
    Publication date: July 12, 2007
    Inventor: Yong-Seok Park