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.

Abstract: Methods are provided for forming current perpendicular to the plane thin film read heads. In one embodiment, the method comprises the steps of forming a lower sensor lead, forming a lower sensor lead cladding of a low sputter yield material on the lower sensor lead, forming a sensor element on the lower sensor lead cladding, and forming an upper sensor lead coupled to the sensor element. The low sputter yield material helps to reduce redeposition of the lower sensor lead material onto side walls of the sensor element as the sensor element is being formed.

Abstract: A thermal spray mixed with a substrate using a non-consumable cylindrical rotating tool. The process may be repeated to create a composite-like coating or material. The coating or material may be machine to improve surface quality.

Abstract: A method of maintaining a non-obstructed interior opening in a kinetic spray nozzle is disclosed. The method includes the steps of providing a mixture of particles including first particle population and a second particle population; entraining the mixture of particles into a flow of a gas at a temperature below the melt temperature of the particle populations; and directing the mixture of particles entrained in the flow of gas through a supersonic nozzle to accelerate the first particle population to a velocity sufficient to result in adherence of the first particle population on a substrate positioned opposite the nozzle. The operating conditions of the kinetic spray system are selected such that the second particle population is not accelerated to a velocity sufficient to result in adherence when it impacts the substrate.

Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.

Abstract: In one embodiment, a method for coating an article, comprises: masking an area of an article with a mask comprising elemental tungsten at least on a surface of the mask opposite the article, heating a coating material, directing the material at the article and the mask, and forming a coating of the material on the article. In another embodiment, the method for coating an article comprises: masking an area of an article with a mask comprising a material having melting point of greater than or equal to about 2,000° C., a start of oxidation temperature of greater than or equal to 400° C., in air, heating a material, directing the heated material at the masked article, and forming a coating of the material on the article. A difference in a mask coefficient of thermal expansion and a coating material coefficient of thermal expansion is greater than or equal to about 10%.

Abstract: The present invention relates to a method including thermal spraying a chromium nitride or a chromium carbide and chromium silicide coating material on to an article. The coating material may be in a powder form before thermal spraying. In one aspect, the thermal spraying includes melting the coating material, propelling the molten coating material toward the article to be coated, and coating the article with the molten coating material. In another aspect, the coated article is one or more piston rings.

Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition comprises a mixture of metal-clad solid lubricant particles and unclad solid lubricants particles for producing an abradable seal used in the compressor section of gas engines, aircraft engines, radial compressors and the like. The metal is selected from alloys of Ni, Co, Cu, Fe and Al, preferably Ni alloys, and the solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride and molybdenum disulphide, preferably hexagonal boron nitride or hexagonal boron nitride and graphite.

Abstract: Disclosed herein is a transfer-laminating member comprising a heat-resistant base material, a release layer provided in part or in whole on the base material and a surface-protecting layer releasably provided on the release layer and formed by applying and drying a coating formulation with a material for forming the surface-protecting layer dissolved in an organic solvent, wherein the release layer contains particles and is formed by curing a mixture which comprises of a silicone resin, a melamine resin and an alkyd resin.

Abstract: A fiber-reinforced plastic base body is first of all provided with a coating of hard rubber or thermoplastic having a dispersed metal or ceramic content of 5% by volume to 80% by volume, and the coating is ground down to provide a smooth surface In a further step a layer of metal and/or ceramic, which has a printing function, is applied to the smooth surface, preferably by thermal spraying.

Abstract: Manufacturing low density components of high surface strength having a polymer or metal matrix substrate and ceramics and/or metal-ceramics coating, wherein the low density substrate to be coated is subjected to: optionally, machining the surface in order to generate residual compressive stress in the outer layers; optionally, thermal stabilizing at a temperature lower than 350° C.; depositing onto the outer surface, with hot spraying techniques at a temperature ranging from 70 to 350° C., of a coating layer in ceramics and/or metal-ceramics material of a surface strength higher than that of the component to be coated, the surface of the coating layer being optionally subjected to a finishing treatment. The disclosure also relates to the product thus obtained.

Abstract: A thermal spray method for the fabrication of ceramic/metal and ceramic/ceramic hardcoating for wear applications. The method makes use of feedstock powder, composed of micron-scale aggregates of hard phase material particles that are either mixed or coated with a readily fusible nano-scale binder phase material. Thus, during thermal spraying, the nanostructured material undergoes rapid melting while the aggregated material is heated but not necessarily melted. A dense coating is formed when the molten nano-material fills the available pore spaces between the heated and softened aggregates, providing a strong and tough matrix for the consolidated material. Optimal wear properties are achieved when the volume fraction of aggregated particles is high, typically in the range of 0.5-0.9. Aggregated material may be composed of one, two or more particles of difference sizes and/or compositions, with particle size distribution that gives high packing density for the hard phase.

Abstract: A method for the production of a heater element on a target area. A plurality of particles having a specified size range are prepared. The plurality of particles include a metallic alloy, and the metallic alloy includes boron. The particles are applied to the target area using at least one of a plasma spray process and a flame spray process.

Abstract: The present invention relates to methods for selectively enhancing corrosion protection of fabricated metal parts. One method of the present invention includes providing a non-galvanized metal sheet to be processed to form the fabricated metal part; selecting a localized region on the non-galvanized metal sheet; roughening the localized region for acceptance of a protective coating; applying a protective coating to localized region; and fabricating the non-galvanized metal sheet into a fabricated metal part. Another method includes providing a galvanized metal sheet; selecting a localized region on the galvanized metal sheet; applying a protective coating to the localized region; and fabricating the galvanized metal sheet into a fabricated metal part. Yet another method includes selecting a localized region on a fabricated metal part; roughening the localized region for acceptance of a protective coating; and applying the protective coating to the localized region.

Abstract: The present invention provides an improved multi-layer composite of two or more polymeric layers at least one of which is formed from a thermosetting composition. The composite includes at least a first polymeric layer formed on a substrate and a second polymeric layer over the first polymeric layer, wherein in the absence of a boron-containing compound, the first and second polymeric layers have poor interlayer adhesion. The improvement resides in the inclusion of at least one boron-containing compound in one or both of the first and second polymeric layers in an amount sufficient to improve the interlayer adhesion between the first and second polymeric layers. Also provided is an improved curable coating composition used to form a multi-layer composite coating of two or more cured coating layers, at least one of which is formed from the thermosetting composition. Related methods and coated substrates are also provided.

Abstract: To improve the machining and processing, respectively, as well as the tribologic properties of ferrous coatings for the working surfaces of combustion engine cylinder blocks applied by a plasma spraying operation, a ferrous coating having a content of bound oxygen in the amount of between 1 to 4% by weight is suggested. Such coatings can be realized, for example, by adding an amount of 200 to 1000 normalized liters air per minute during the plasma spraying operation.

Abstract: A method for making an aluminum substrate that is subjected to repeated impaction more wear resistant. The method comprises applying at least about 0.005 inch thick coating of an amorphous composition directly to only portions of this substrate, preferably after it is shaped into a product for transporting consumable materials. The coating composition to which steel, aluminum, PTFE and/or polyethylene may be added, can be thermally sprayed to the substrate surface.

Abstract: Corrosion-resistant, oxidation-resistant, and/or wear-resistant coatings are made of ternary ceramic compounds of the general formula (I): M2X1Z1   (I) wherein M is at least one transition metal, X is an element selected from the group consisting of Si, Al, Ge, Pb, Sn, Ga, P, S, In, As, Tl and Cd, and Z is a non-metal selected from the group consisting of carbon and nitrogen; and/or compounds of the general formula (II): M3X1Z2   (II) wherein M is at least one transition metal, X is at least one of Al, Ge, and Si, and Z is at least one of carbon and nitrogen. Such coatings may be applied by a thermal spraying process.

Abstract: A method of treating the surface of a substrate by thermally spraying large size particles, >10 micrometers, of a composition such as a metal hydroxide, carbonate, or nitrate directly onto the substrate whereby a small size particle coating, <5 microns and more particularly <3, is formed on the substrate, enhancing the surface area and porosity properties of the substrate, and substrates with metal oxide surfaces produced thereby.

Abstract: A multi-layer thermal barrier coating for a superalloy article includes a metallic matrix coating containing particles, a MCrAlY alloy bond coating on the metallic matrix coating, a thin oxide layer on the MCrAlY alloy bond coating and a columnar grain ceramic thermal barrier coating. The metallic matrix coating includes a 80 wt % nickel-20 wt % chromium alloy. The particles include metallic compounds such as carbides, oxides, borides and nitrides, which react with harmful transition metal elements such as titanium, tantalum and hafnium, in the superalloy substrate. One suitable compound is chromium carbide because the hafnium transition metal elements will take part in an exchange reaction with the chromium in the chromium carbide to form a stable carbide of the harmful transition metal element. This reduces the amount of harmful elements in the superalloy reaching the oxide layer and increases the service life of the thermal barrier coating.

Abstract: A material in powder or wire form on a nickel basis for the production of a coating with a high level of resistance to corrosion and wear by means of a thermal coating process is of the following composition (in percent by weight): C 0.005-1.0;  Cr 10.0-26.0; Mo  8.0-20.0; Fe  0.1-10.0; Si 3.0-7.0; B 1.0-4.0; Cu 0.1-5.0; Ni Balance. The material in powder form can be alloyed and sprayed out of the melt or agglomerated out of different alloyed and non-alloyed metal powders. The coating material can also be used in the form of a filling wire or an alloyed and cast bar material.

Abstract: A spray powder which has a particle size of from 6 to 63 &mgr;m and which comprises from 75 to 95 wt % of a ceramic phase made of a WC powder and at least one chromium carbide powder selected from the group consisting of Cr3C2, Cr7C3 and Cr23C6, and from 5 to 25 wt % of a metal phase made of a Ni or Ni-based alloy powder, wherein the mean particle size of primary particles of the WC powder constituting the ceramic phase is from 5 to 20 &mgr;m, and the mean particle size of primary particles of the chromium carbide powder is from 1 to 10 &mgr;m.

Abstract: A thermal spraying method involves the creation of a coating comprising titanium wire in the presence of nitrogen. The apparatus of the invention comprises a nozzle which has a cylindrical throat, with feedstock guides which guide the feedstock wires to a point of intersection in the throat. A current is passed through the wires to cause an arc in the throat, and a nitrogen rich gas under pressure is forced through the throat, generating a spray of molten particles which is used to coat a substrate. In a variation of the method, one of the feedstock wires comprises a binder metal, which produces a coating having enhanced toughness.

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 hard carbon film is formed over an inner surface of a guide bush by fixing an auxiliary electrode support member for supporting an auxiliary electrode of a jig for forming a film in a center bore of the guide bush by an auxiliary electrode insulation member, disposing an auxiliary electrode in alignment with the axis of the center bore so as to face the inner surface, disposing legs, and a first electrode plate, a second electrode plate, and the insulation member which are fixed to the legs are placed on the bottom of a vacuum vessel placing the guide bush on the first electrode plate contacted electrically with a power source, while the projection of the auxiliary electrode support member projecting out of the auxiliary electrode insulation member is contacted electrically with the second electrode plate.

Abstract: A steel bearing member having an erosion resistant surface and a method of making the same is disclosed. The steel bearing member comprising a bearing substrate, a first overlay of hardbanding material having sintered cemented metal carbide pellets in steel and containing hard submicron sized particles, and a second overlay of steel containing hard particles that migrated from the first overlay of hardbanding material during application of the second overlay over the first overlay. A radial bearing member and a method of making the same is disclosed. A composition applied to the bearing substrate to improve the erosion resistance of this surface comprising a steel carrier and carbide pellets composed of submicron hard particles cemented with a metal binder is disclosed.

Abstract: In a method of coating easily oxidisable materials by plasma powder build-up welding of additive materials in powder form using alternating current or direct current with superimposed alternating current to produce a plasma transferred arc for powder build-up welding in accordance with patent application No 196 26 941.5 a CuNi-alloy is used as an additive welding material with additions (in % by weight) of:______________________________________ Fe below about 10; Cr below about 5; B below about 4; Si below about 4; C with about 1.5; ______________________________________with a degree of mixing of more than 40% by volume.

Abstract: The present invention provides a method of and apparatus for efficiently and continuously manufacturing large, thin-film-coated substrates (i.e. antireflection filters) via small-scale manufacturing apparatus. The apparatus includes a film-forming chamber, two stockers, each capable of storing substrates in multi-stages, a loading chamber and an unloading chamber. The film forming area is centrally positioned, surrounded upstream and downstream by each stocker with loading and unloading chambers positioned upstream and downstream of the stockers, respectively. The film-forming chamber, the loading and unloading chamber and each stocker have, respectively, independent evacuation systems. The film forming chamber also contains a particle generation source and apparatus for passing a substrates, one after another, from the first stocker, in to the film-forming chamber and out to the second stocker.

Abstract: Structural ceramic matrix composite material to be employed as automotive engine parts and the like is provided with erosion-resistant qualities in several ways. For one, an erosion-resistant material is applied to the surface as by plasma spraying. The erosion-resistant material can also be mixed with the fibers of the material, particularly near the surface.

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: A carbon coated metal powder depositable by thermal spray techniques to form a metal coating is disclosed. The carbon coated metal powder has a composition comprising a metal powder and carbon adhered to the metal powder. The metal powder is coated with carbon to form a carbon coated metal powder. The carbon coated metal powder, after being thermally sprayed on to a substrate and after being formed into a metal coating on the substrate, has an oxygen content at least 20% by weight less than the oxygen content in the carbon coated metal powder prior to being thermally sprayed.

Abstract: A method for producing an atomized powder of chromium carbide particles dispersed in a nickel chromium matrix in which chromium in the powder is from 55 to 92 weight percent of the powder.

Abstract: Known thermal spray apparatus are modified to achieve thermal spray coatings of increased hardness. Thermal spray apparatus operate to develop a plasma stream for introduction to a nozzle, for eventual application to the surface of a substrate. Upon entering the nozzle, the plasma stream is passed through a plasma cooling zone defined by a plasma cooling passageway, to a plasma accelerating zone defined by a narrowed passageway that expands into a plasma/particle confining zone for the discharge of material from the apparatus. The narrowed passageway of the apparatus is cooled, and the powder material to be applied by the apparatus is introduced into the plasma stream along the cooled, narrowed passageway.

Abstract: Disclosed is a bearing unit which can be used in a drainage pump operated without supply of clean water or a hydraulic pump, which exhibits excellent wear resistance against water containing earth and sand and satisfactory assembling facility, and a method of manufacturing the bearing unit.The contact surface of a bearing made of stainless steel and/or that of a sleeve is applied with a sprayed coating, the main component of which is WC, and which contains one or more elements selected from a group consisting of nickel, chromium and cobalt as a binder material thereof, or a sprayed coating, the main component of which is Cr.sub.3 C.sub.2, and which contains NiCr as a binder material, after the sprayed coating has been formed, heating at from 300.degree. C. to 550.degree. C. is performed for one hour or longer so that hardness and wear resistance equivalent to those of a WC-12% sintered article is attained.

Abstract: A composite material comprising a matrix including chromium carbide particles, and a solid lubricant mixed with the matrix and including barium fluoride and calcium fluoride. The composite material is spray deposited onto a substrate using a high velocity oxy-fuel (HVOF) spray technique to provide an HVOF spray coating.

Abstract: A process for reducing oxygen content in thermally sprayed metal coatings comprises the following steps. A metal powder is provided. The metal powder has a particle size in the range of from about 10 .mu.m to about 500 .mu.m. Carbon is adhered and coated to the metal powder to form a carbon coated metal powder. The carbon is present in the range of from about 0.1% to about 2.0% by weight of the carbon coated metal powder. The carbon coated metal powder is thermally sprayed onto a substrate and a metal coating is deposited on the substrate. The metal coating has a lower oxygen content compared to the oxygen content of the carbon coated metal powder.

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 hard-facing material source is an article whose net composition is, in weight percent, from about 20 to about 35 percent chromium, from about 2 to about 5 percent boron, from about 1 to about 2.5 percent silicon, from 0 to about 0.5 percent carbon, from about 0.5 to about 2 percent manganese, and from about 0.2 to about 1.0 percent titanium, balance iron and incidental impurities. The article may be a powder or a hollow tube with a powder packed therein. The hard-facing material source is thermally applied to a substrate by spraying or welding.

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 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 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 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 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 method of improving the erosion resistance of the surface of a metal substrate by the technique of applying a dense and adherent alloy coating comprised of niobium carbide in a ductile matrix such as cobalt-chromium to the substrate surface using a hypersonic flame spray gun.

Abstract: A method is disclosed for the electric arc spraying of powder-filled cored wires to apply hard, wear-resistant coatings to various substrates. Inert gas, preferably nitrogen, is supplied to the arc spray gun such that the mass ratio of the wire feed rate to the gas feed rate is preferably between about 0.07 and about 0.11. Operation in this range yields an optimum combination of coating hardness properties and arc spray gun operating characteristics.

Abstract: A method of the 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.