Abstract: A method of extending storage time prior to cleaning a component of a plasma chamber is provided. The method comprises removing the component from the chamber, covering a thermal spray coating on the component while the surface is exposed to atmospheric air, storing the component, optionally removing the covering, and optionally wet cleaning reaction by-products from the thermal spray coating. Alternatively, instead of, or in addition to covering a thermal spray coating on the component, the component can be placed into a desiccator or dry-box.

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).

Abstract: Processes for depositing conductive materials on substrates are disclosed which include the steps of combusting a premixed fuel and oxidant to form a stagnation flame against a moving surface which stabilizes the stagnation flame and introducing at least one precursor to the flame to form a conducting material onto the substrate.

Abstract: This invention relates to dense, vertically cracked thermal barrier coatings made from high purity yttria or ytterbia stabilized zirconia powders. The high purity yttria or ytterbia stabilized zirconia powder consisting essentially of less than about 0.01 weight percent silicon dioxide (silica), less than about 0.002 weight percent aluminum oxide (alumina), less than about 0.005 weight percent calcium oxide, less than about 0.005 weight percent ferric oxide, less than about 0 to about 0.002 weight percent magnesium oxide, less than about 0 to about 0.005 weight percent titanium dioxide, from about 1.5 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria), less than 0.1 weight percent other impurity oxides, and the balance zirconium oxide (zirconia) and the balance zirconium oxide (zirconia).

Abstract: A method and apparatus for making an optical fiber preform, including injecting a plasma gas source into the first end of a tubular member; generating a ring plasma flame with the plasma gas source flowing through a plasma gas feeder nozzle, the plasma gas feeder nozzle including: an inner tube, an outer tube, wherein the plasma gas source is injected between the inner tube and the outer tube to produce the ring plasma flame, such that at least a portion of the ring plasma flame is directed radially toward the inner surface of the tubular member; traversing the tubular member along the longitudinal axis relative to the plasma flame; depositing at least one soot layer on the interior surface of the tubular member by introducing reagent chemicals into the plasma flame; and fusing all of the soot layers into a glass material on the interior surface of the tubular member.

Abstract: A transition metal/carbon nanotube composite includes a carbon nanotube and a transition metal oxide coating layer disposed on the carbon nanotube. The transition metal oxide coating layer includes a nickel-cobalt oxide.

Abstract: A substrate processing chamber component comprising a chamber component structure having an yttrium-aluminum coating. The yttrium-aluminum coating comprises a compositional gradient through a thickness of the coating.

Abstract: In a nuclear power plant, a corrosion-resistant oxide film on a surface of the metal component of a reactor structure is exposed to a high-temperature water, the corrosion-resistant oxide film containing an oxide having a property of a P-type semiconductor, and a catalytic substance having a property of an N-type semiconductor is deposited on the oxide film. The oxide film maintains the property of the P-type semiconductor.

Abstract: The invention relates to a catalytic coating suitable for oxygen-evolving anodes in electrochemical processes. The catalytic coating comprises an outermost layer with an iridium and tantalum oxide-based composition modified with amounts not higher than 5% by weight of titanium oxide.

Abstract: Intermediates and methods for forming activated metal complexes bound to surfaces on oxide layers, immobilizing beads to the modified surface and articles produced thereby are described. Hydroxyl groups on the oxide surfaces are reacted with a metal reagent complex of the formula Y(L-Pol)m, where Y is a transition metal, magnesium or aluminum, L is oxygen, sulfur, selenium or an amine, and “Pol” represents a passivating agent such as a methoxyethanol, a polyethylene glycol, a hydrocarbon, or a fluorocarbon. The resulting modified surface can be further reacted with a passivating agent having a phosphate functional group or a plurality of functional groups that are reactive with or that form complexes with Y.

Abstract: A fuel electrode anode (18) for a solid oxide fuel cell is made by presenting a solid oxide fuel cell having an electrolyte surface (15), mixing copper powder with solid oxide electrolyte in a mixing step (24, 44) to provide a spray feedstock (30,50) which is fed into a plasma jet (32, 52) of a plasma torch to melt the spray feed stock and propel it onto an electrolyte surface (34, 54) where the spray feed stock flattens into lamellae layer upon solidification, where the layer (38, 59) is an anode coating with greater than 35 vol. % based on solids volume.

Abstract: Process for producing at least one nanoporous layer of nanoparticles chosen from nanoparticles of a metal oxide, nanoparticles of metal oxides, and mixtures of said nanoparticles, on a surface of a substrate, in which at least one colloidal sol, in which said nanoparticles are dispersed and stabilized, is injected into a thermal plasma jet which sprays said nanoparticles onto said surface. Nanoporous layer and device, especially a separation device, comprizing said layer.

Abstract: Target of nominal thickness (e), comprising at least one molybdenum-based compound, characterized in that it has: a lamellar microstructure; an oxygen content of less than 1000 ppm, preferably less than 600 ppm, and even more preferably less than 450 ppm; and an electrical resistivity less than five times, preferably three times and more preferably twice the theoretical electrical resistivity of the compound.

Abstract: An implantable medical device includes a housing and a coating disposed on the housing. The coating includes a conductive carrier and a therapeutic agent, e.g. an anti-infective agent such as silver particles. The conductive carrier can be any suitable conductive material, such as iridium oxide, titanium nitride, diamond-like carbon, graphite, polyaniline, platinum, carbon nanotubes, carbon black, platinum black, or poly 3,4,-ethylenedioxythiophene. Coatings containing iridium oxide and metallic silver particles are effective in inhibiting bacterial growth in vitro.

Abstract: Methods for coating a substrate are disclosed, the methods comprising providing a substrate, providing pre-formed nanoparticles of an inorganic material, providing at least one precursor of a first metal oxide, and depositing a coating on at least one surface of the substrate by contacting the surface with the precursor of the metal oxide and pre-formed nanoparticles. Also disclosed are substrates coated using such a method. The coated substrates are coloured. Preferably the metal oxide is a doped metal oxide to modify the thermal properties of the coating. The preferred nanoparticles are of platinum group metals or coinage metals.

Abstract: A process for forming a coating system on a turbine engine component comprises the steps of providing a substrate, depositing a thermal barrier coating on the substrate, depositing a reactive with known CMAS reaction kinetics on the thermal barrier coating, and activating the reactive layer prior to the component being placed in service. As a result of the foregoing process, there is provided a turbine engine component which has a substrate, a thermal barrier coating deposited on the substrate, a reactive layer deposited on the thermal barrier coating, which reactive layer has known CMAS reaction kinetics and is activated prior to the turbine engine component entering into service.

Abstract: Amorphous mixed metal oxides are used as a feedstock for thermal spray coating. Compared to thermal spray coating methods utilizing crystalline metal oxide feedstocks, the present method reduces energy consumption and expands the range of feedstock chemical compositions. The present method also produces coatings with improved chemical homogeneity. Methods of preparing the amorphous mixed metal oxides are also described.

Abstract: Provided is a method of fabricating, with satisfactory adhesion, a thin film of a metal or a metallic-compound, such as a metal oxide or nitride, on a substrate made of a high-melting-point material such as silicon or ceramics by using a metal or metallic-compound target as the primary raw material so as to eliminate the necessity of using harmful gases such as organometallic gas, and by using an atmospheric-pressure plasma generated under atmospheric pressure as a reaction field and also as a heat source. Additionally provided is an apparatus for fabricating the thin film.

Abstract: A superconducting article includes a substrate having an untextured metal surface; an untextured barrier layer of La2Zr2O7 or Gd2Zr2O7 supported by and in contact with the surface of the substrate; a biaxially textured buffer layer supported by the untextured barrier layer; and a biaxially textured superconducting layer supported by the biaxially textured buffer layer. Moreover, a method of forming a buffer layer on a metal substrate includes the steps of: providing a substrate having an untextured metal surface; coating the surface of the substrate with a barrier layer precursor; converting the precursor to an untextured barrier layer; and depositing a biaxially textured buffer layer above and supported by the untextured barrier layer.

Abstract: A thermal spray powder includes granulated and sintered yttria particles obtained by granulating and sintering a raw material powder in air or oxygen. The primary particles constituting the granulated and sintered yttria particles have an average particle size between 0.5 and 1.5 ?m inclusive, and 1.11 times or more as large as the raw material powder. Alternatively, the primary particles have an average particle size between 3 and 8 ?m inclusive.

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.

Abstract: The invention relates to methods of gas detonation deposition (gas detonation explosion) applying coatings, especially layers of materials for electrochemical devices for use as electrodes in electrochemical energy generation and storage devices such as batteries, supercapacitors, photovoltaic cells, and the like. In the method of the gas detonation deposition the powders of the materials, which are deposited, are subjected to detonation with the explosion products flow. As a result, the powder particles gain a high kinetic energy and are deposited on a substrate, forming a high quality coating.

Abstract: A method and apparatus for forming an electrochemical layer of a lithium ion battery is provided. A precursor mixture in a carrying medium is activated in a reactor chamber by application of energy to synthesize active materials. The activated precursor mixture is then spray deposited on a substrate. A binder and conductive materials may be blended, or sprayed separately, with the nano- or micro-crystals as they deposit on the surface to enhance adhesion and conductivity.

Abstract: A cutting tool insert, particularly useful for machining of steel and stainless steel, comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel a hard and wear resistant coating; and at least (Al,Cr)2O3 layer applied to said body is disclosed. Methods of making a cutting tool insert are also disclosed. In addition, methods for machining of cast iron using the cutting tool inserts are disclosed.

Abstract: Disclosed is a method for producing a coating system on a component, wherein at least one coating is deposited on the component by way of atmospheric plasma spraying (APS) and at least one further coating is deposited by way of suspension plasma spraying (SPS). The coatings are particularly advantageously deposited in the sequence of APS+SPS or APS+SPS+APS or APS+SPS+erosion coating. These sequences of coatings applied in this way usually have an effect providing a first porous coating and a second porous coating disposed thereon, wherein the porosity of the second coating is greater than that of the first coating, and wherein the reflectivity is greater than that of the first coating.

Abstract: High performance coated metal compositions resistant to metal dusting corrosion and methods of providing such compositions are provided by the present invention. The coated metal compositions are represented by the structure (PQR), wherein P is an oxide layer at the surface of (PQR), Q is a coating metal layer interposed between P and R, and R is a base metal. P includes alumina, chromia, silica, mullite or mixtures thereof. Q includes Ni and Al, and at least one element selected from the group consisting of Cr, Si, Mn, Fe, Co, B, C, N, P, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au and mixtures thereof. R is selected from the group consisting of carbon steels, low chromium steels, ferritic stainless steels, austenetic stainless steels, duplex stainless steels, Inconel alloys, Incoloy alloys, Fe—Ni based alloys, Ni-based alloys and Co-based alloys.

Abstract: Described is a method for the production of pure or mixed metal oxides, wherein at least one metal precursor that is a metal carboxylate with a mean carbon value per carboxylate group of at least 3, e.g. the 2-ethyl hexanoic acid salt, is formed into droplets and e.g. flame oxidized. The method is performed at viscosities prior to droplet formation of usually less than 40 mPa s, obtained by heating and/or addition of one or more low viscosity solvents with adequately high enthalpy.

Abstract: Plasma-sprayed layers of aluminium oxide on a substrate are produced by using a pyrogenically produced aluminium oxide, for example selected from the group consisting of borosilicate and steel, as starting powder.

Abstract: The present invention relates to a method for manufacturing a transparent oxide electrode using an electron beam post-treatment. The method for manufacturing a transparent oxide electrode comprises the steps of: (a) forming a thin film for the transparent anode on a substrate; and (b) irradiating an electron beam to the surface of the thin film for the transparent oxide electrode. The method of the present invention is characterized in that no additional heat treatment process is performed after step (a). The method for manufacturing a transparent oxide electrode according to the present invention does not perform a high-temperature heat treatment process but rather performs a low-temperature electron beam irradiation process as a post-treatment, thus obtaining a transparent oxide electrode having excellent characteristics in case where the substrate is made of glass, Pyrex, quartz or even a polymer material which has a low resistance against heat.

Abstract: A plasma spray process, comprising the following steps: providing a first material; providing a second material; providing a plasma source; and introducing the first and second materials into the plasma source in order to produce a plasma spray, wherein the second material at least partially melts in the plasma and binds the first material. A composition of matter formed by such a process. A substrate modified by such a process.

Abstract: A housing for an electronic device includes a metal substrate and a ceramic coating directly formed on at least portions of the substrate, the coated portions of the substrate having a rough surface. A method for fabricating the housing comprises roughening predetermined portions of the substrate; thermally spraying a ceramic coating on the roughened portions of the substrate, fixing the substrate on a tool having cold water circularly running there within during the thermal spraying; and grinding and polishing the ceramic coating.

Abstract: A coating suitable for use as a wear-resistant coating for a gas turbine engine component comprises a lubricating material and a hard carbide material.

Abstract: Ceramic abradable materials, in particular thermally sprayable ceramic abradable powder materials, and abradable seals formed by thermally spraying the materials include dysprosia (Dy2O3) and zirconia (ZrO2). Coatings are porous whereby the porosity, in part, is induced by plastic or fugitive phases. Abradable seal coatings comprising dysprosia and zirconia exhibit improved thermal shock and sintering resistance and can be worn into tolerance by untreated, bare turbine blades, at least in certain regimes of relative blade speed and coating porosity. Ceramic abradable seal coatings comprising dysprosia and zirconia can be used up to 1200° C.

Abstract: A wind power plant is provided including at least one component with a surface. The surface is coated at least partially with a hard material layer, preferably a vanadium-based hard material layer. Further, a wind park and a method of improving a characteristic of a surface of a component of a wind power plant are provided.

Abstract: A process for forming a coating on a substrate, such as a turbine engine component, is provided. The process comprises the steps of: providing a first rare earth oxide stabilized zirconia composition; providing a second composition selected from the group consisting of a yttria stabilized zirconia composition, a ceria stabilized zirconia composition, alumina, a chromia-alumina composition, a gadolinia stabilized zirconia composition, and mixtures thereof; blending the first rare earth oxide stabilized zirconia composition with the second composition to form a blended powder; and depositing the blended powder onto the substrate. Articles having the coating formed from the above process are also described.

Abstract: Methods of laser assisted plasma coating at atmospheric pressure including providing a plasma, at least one target, at least one laser, and a superalloy substrate, operably directing the laser toward the target to liberate atomic particles from the target and feed the atomic particles into the plasma, and depositing the atomic particles onto the superalloy substrate using the plasma to produce a thermal barrier coating having a column width of from about 0.5 microns to about 60 microns, and an intra column porosity of from about 0% to about 9%.

Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.

Abstract: The invention relates to thermally sprayed Al2O3 layers having a high content of corundum without any property-reducing additives, and to a method for the production of said layers. The invention may be utilized particularly in the field of electrical insulation, as a dielectric, and as protection from wear. According to the invention, the thermally sprayed Al2O3 layers are characterized in that they have a porosity of no more than 19%, and a high content of ?-Al2O3 (content of corundum) of at least 72% by volume. The layers have a specific electrical resistance of >1·1012 Ohms·cm, and a purity of >97%. The production according to the invention of said layers is carried out utilizing aqueous or alcoholic suspensions made from pure ?-Al2O3, having a grain size of >100 nm by means of a method from the group of thermal spraying.

Abstract: A gas turbine article includes a substrate, a plurality of geometric surface features that protrude from the substrate, and a thermally insulating topcoat disposed over the plurality of geometric surface features. The thermally insulating topcoat includes segmented portions that are separated by faults that extend through the topcoat from the geometric surface features.

Abstract: A turbine component has an airfoil extending between a leading edge and a trailing edge, and has an outer surface. A coating includes at least two discontinuous areas that are spaced from each other such that there is an area of uncoated surface between the discontinuous areas of coating. In addition, a method of providing such a coating is disclosed.

Abstract: A method of producing an oxide dispersion strengthened nickel-base superalloy, comprising introducing an oxide dispersoid material into a plasma gun of a plasma spray apparatus, where it is sublimed and turned to vapour; and introducing a nickel-base superalloy material into the plasma spray apparatus at a cooler location, downstream of the plasma gun, such that the oxide dispersoid material condenses on the superalloy material to produce the oxide dispersion strengthened nickel-base superalloy.

Abstract: The present invention is directed to a method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000° C. The method includes the step of providing the metal surfaces in such applications with a hot erosion resistant cermet lining or insert, wherein the cermet lining or insert includes a) about 30 to about 95 vol % of a ceramic phase, and b) a metal binder phase, wherein the cermet lining or insert has a HEAT erosion resistance index of at least 5.0 and a K1C fracture toughness of at least 7.0 MPa-m1/2. The metal surfaces may also be provided with a hot erosion resistant cermet coating having a HEAT erosion resistance index of at least 5.0.

Abstract: A method to use a novel structured metal-ceramic composite powder to improve the surface electrical conductivity of corrosion resistant metal substrates by thermal spraying the structured powder onto a surface of a metallic substrate is disclosed. The structured powder has a metal core and is wholly or partially surrounded by an electrically conductive ceramic material such as a metal nitride material. The metal cores may have the ceramic material formed on them prior to a thermal spraying process performed in an inert atmosphere, or the thermal spraying may be performed in a reactive atmosphere such that the ceramic coating forms on the cores during the thermal spraying process and/or after deposition. The metal cores will bond conductive ceramic material onto the surface of the substrate through the thermal spray process.

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.

Abstract: An article, at least a surface of the article being made of or containing an organic material, and a thermally sprayed layer of coating material on the surface.

Abstract: A mold, comprising: a substrate, the substrate having an inside surface and an outside surface; and a ceramic coating formed on at least substantially the entire inside surface, the ceramic coating comprising chromic oxide, silicon dioxide, and alumina. A method for making the present mold is provided.

Abstract: The present invention provides an improved electrostatic chuck for a substrate processing system. The electrostatic chuck comprising a main body having a top surface configured to support the substrate, a power supply to apply a voltage to the main body and a sealing ring disposed between the main body and the substrate wherein the sealing ring has a conductive layer.

Abstract: A method for forming functional ceramic films on ceramic materials, to enhance mechanical properties, chemical stability, and/or biological properties of the materials. The functional ceramic film comprises at least about 10 weight percent pure zirconia, with phase transformation at tetragonal/cubic phases at high temperature to monoclinic phase at room temperature, leading to volume expansion and compressive stress. The compressive stress enhances mechanical strength, wear resistance, hardness and other properties, and also tends to eliminate cracks and flaws in the ceramic material. The functional film may also include bioactive materials, and may include a structure for eluting drugs so as to serve as a drug delivery vehicle. The functional ceramic films may be centered on the base ceramic, or the materials may be co-centered. Devices having the ceramic materials with functional films may be used, for various medical or dental purposes.

Abstract: It has been surprisingly found that injecting ceria-based particles (mean size less than 200 nm) suspended in a combustible organic solvent into a plume having a maximum temperature between about 2,600° C. and 4,000° C. to impart a mean temperature to the particles from about 2,600° C. to about 3,800° C., and to accelerate the particles to a mean velocity between about 600 to 1000 m/s, produces a thin, uniform, dense, crack-free, nanocrystalline ceria-based coating, which may be applied on porous cermet or metal substrate, for example. The physical environment of a high-velocity oxy-fuel (HVOF) thermal spraying gun suitably ably deployed using standard fuels produces these conditions. The method of the present invention is particularly useful for the cost-effective fabrication of ceria-containing electrolytes for solid oxide fuel cells (SOFCs).

Abstract: The present invention is an integral composite structural (ICS) material comprising an open metal structure having at least one external side and internal surfaces defining a plurality of open shapes with a ceramic matrix composite bonded to at least one external side and the surfaces of at least a substantial portion of the plurality of open shapes and occupying at least a substantial portion of the plurality of open shapes. The open metal structure, independent of the ceramic matrix composite, has a total metal volume percent in the range of about 10% to about 90%, with no dimension of any open shape being greater than about ¾ inch. The ceramic matrix layer covers a substantial portion of at least one external side of the open metal structure.