Abstract: A part made from a composite material having a ceramic matrix and including a protection device, the protection including a coating layer having a gradual composition. The gradual-composition coating layer includes at least one silicon phase and one aluminium phase, the proportions of which change according to the height in the layer, with a first height in the gradual-composition coating layer corresponding to a silicon-free composition, and a second height corresponding to an aluminium-free composition. A method for producing such a protection, and to a device for carrying out the method, are disclosed.

Abstract: A repair method for a gas turbine blade. The repair method include: a step of removing a thermal barrier coating to expose at least part of a base material of the gas turbine blade; a first etching step of etching the exposed base material; and a first identification step of identifying a base material deterioration layer that is harder than the base material from the etched base material. The repair method further includes a first removal step of removing the identified base material deterioration layer if the base material deterioration layer is identified in the first identification step; and a step of applying a thermal barrier coating to the exposed base material. The thermal barrier applying step is performed after it is determined that there is no base material deterioration layer in the first identification step, or after the base material deterioration layer is removed in the first removal step.

Abstract: A method of removing a ceramic coating from a ceramic coated metallic article without damaging the metallic bond coating, the metallic article having a first and second portions, each of the portions comprising a metallic bond coating and a ceramic coating on the metallic bond coating, the ceramic coating on the second portion being less porous than the ceramic coating on the first portion. The method comprises the steps of a) immersing the ceramic coated metallic article in a caustic solution; b) maintaining the ceramic coated metallic article in the caustic solution at atmospheric pressure for a predetermined time period and at a predetermined temperature; c) removing the ceramic coated metallic article from the caustic solution; d) rinsing the ceramic coated metallic article in water at ambient temperature; e) water jet blasting the first portion of the metallic article to remove the ceramic coating; and f) water jet blasting the second portion of the metallic article to remove the ceramic coating.

Abstract: A material for cold spraying contains a powder of a compound of a rare earth element with a specific surface area of 30 m2/g or more as determined by a BET single-point method. The powder preferably has a volume of pores with a pore size of 3 to 20 nm of 0.08 cm3/g or more as determined by a gas absorption method. The powder also preferably has a crystallite diameter of 25 nm or less. The powder also preferably has a repose angle of from 10 to 60°. In the L*a*b* color system, the powder also preferably has a value L of 85 or more, a value a of from ?0.7 to 0.7, and a value b of from ?1 to 2.5.

Abstract: Aspects of the disclosure are directed to processing a component. A first coating is removed from a substrate of the component, the substrate including a first hole. Subsequent to removing the first coating from the substrate, a second coating is applied to the substrate, where a portion of the second coating at least partially blocks the first hole. Subsequent to applying the second coating to the substrate, the portion of the second coating is removed to generate a second hole through the second coating. The removal of the portion of the second coating creates a bore in the second coating that provides a clearance from an edge of the first hole on a surface of the substrate that interfaces to the second coating.

Abstract: A gas sensor includes a sensor element, and the sensor element includes a bottomed tubular solid electrolyte, a detection electrode provided on an outer surface of the solid electrolyte, a reference electrode provided on an inner surface of the solid electrolyte. The detection electrode of the sensor element includes a detection electrode section provided at a position on a tip side of an axial direction, an attachment electrode section provided at a position on a base end side of the axial direction, and a lead electrode section provided at a position where the detection electrode section is connected to the attachment electrode section. An insulating layer is provided between a tube of the solid electrolyte and each of the attachment electrode section and the lead electrode section.

Abstract: A system for wirelessly monitoring temperatures of a gas turbine engine comprising a wireless sensor positioned on or in a component of the engine, one or more interrogating antennas capable of transmitting an RF signal to the wireless sensor and receiving an RF return signal from the wireless sensor, and a processing unit capable of interpreting the RF return signal to determine a temperature of the component inside the engine. In an embodiment, the wireless sensor comprises polymer derived ceramics (“PDC”) deposited on an Inconel surface of the engine. In an embodiment, the wireless sensor sustains temperatures up to 1000° C. during long term operation of the part of the engine. In an embodiment, the wireless sensor comprises multiple layers including a metallic patch antenna, a PDC layer, and a bond coat which provides a metallic ground plane for the sensor.

Abstract: A production method for a double-membrane MEMS component includes: providing a layer arrangement on a carrier substrate, wherein the layer arrangement comprises a first membrane structure, a sacrificial material layer adjoining the first membrane structure, and a counterelectrode structure in the sacrificial material layer and at a distance from the first membrane structure, wherein at least one through opening is formed in the sacrificial material layer as far as the first membrane structure; forming a filling material structure in the at least one through opening by applying a first filling material layer on the wall region of the at least one through opening; applying a second membrane structure on the layer arrangement with the sacrificial material; and removing the sacrificial material from an intermediate region to expose the filling material structure in the intermediate region.

Abstract: A piston for an internal combustion engine with a piston crown and a circumferentially arranged crown edge, whereby, near the periphery of the crown edge, a thermal barrier coating is applied, whereby the thermal barrier coating tapers off before the periphery of the crown edge.

Abstract: A turbine blade of a gas turbine engine is described which includes an airfoil extending away from the hub platform to a blade tip. The airfoil defines a leading edge, a trailing edge, and a span-wise length extending between the platform and the blade tip. A hot-corrosion-resistant coating is located on the leading edge of the airfoil within a radially inner portion thereof, the radially inner portion extending away from the hub platform a desired distance along the span-wise length.

Abstract: A layer system is provided having at least two layers, an inner layer on a boundary surface of a substrate, wherein the inner layer has a certain roughness in a region of the surface to an outer layer due to a coating processes, wherein a roughness of the boundary surface of the substrate is set in a targeted manner, or the boundary surface is machined, after it has been produced, such that the roughness of the boundary surface of the substrate has peaks and troughs that are at least 20% greater than the roughness of the interface if peaks and troughs were not to be present. As a result of the structured surface of the substrate, this roughness becomes positioned on an interface of the layers located above, and the adhesion of the layers to one another is thereby improved.

Abstract: To manufacture a coating for an article for a semiconductor processing chamber, the article including a body of at least one of Al, Al2O3, or SiC, and a ceramic coating on the body. The ceramic coating includes a compound comprising Y2O3 in a range from about 50 mol % to about 75 mol %, ZrO2 in a range from about 10 mol % to about 30 mol %, and Al2O3 in a range from about 10 mol % to about 30 mol %, wherein the number of nodules per inch is in a range from about 30 nodules to about 45 nodules and the porosity is in a range from about 2.5% to about 3.2%.

Abstract: A gas turbine engine component includes a substrate formed of a high temperature resistant material and a corrosion resistant layer. The corrosion resistant layer is inert to the molten salt impurities and includes a refractory metal vanadate of formula MxVyOz, wherein M is selected from the group consisting of alkaline earth metals, group IV and V transition metals, rare-earth metals and their combinations, and wherein z=x+2.5y, or z=1.5x+2.5y, or z=2x+2.5y.

Abstract: To apply a thermal barrier coating (10), a plasma jet (5) is generated by a plasma torch in a work chamber (2) and is directed to the surface of a substrate (3) introduced into the work chamber, and a ceramic coating material is applied to the substrate surface by means of PS-PVD, wherein the coating material is injected into the plasma jet as a powder and is partly or completely vaporized there. On applying the thermal barrier coating, in a first workstep the feed rate of the injected powder is set so that a large part of the injected powder vaporizes, wherein the coating material condenses from the vapor phase on the substrate surface and forms mixed phases with the material of the substrate surface.

Abstract: A method of plasma spraying an article comprises inserting the article into a vacuum chamber for a low pressure plasma spraying system. A low pressure plasma spray process is then performed by the low pressure plasma spraying system to form a first plasma resistant layer having a thickness of 20-500 microns and a porosity of over 1%. A plasma spray thin film, plasma spray chemical vapor deposition or plasma spray physical vapor deposition process is then performed by the low pressure plasma spraying system to deposit a second plasma resistant layer on the first plasma resistant layer, the second plasma resistant layer having a thickness of less than 50 microns and a porosity of less than 1%.

Abstract: A multi-layer coating for protection of metals and alloys against oxidation at high temperatures is provided. The invention utilizes a multi-layer ceramic coating on metals or alloys for increased oxidation-resistance, comprising at least two layers, wherein the first layer (3) and the second layer (4) both comprise an oxide, and wherein the first layer (3) has a tracer diffusion coefficient for cations Mm+, where M is the scale forming element of the alloy, and the second layer (4) has a tracer diffusion coefficient for oxygen ions O2? satisfying the following formula: ? ln ? ? p ? ( O 2 ) in ln ? ? p ? ( O 2 ) ex ? ( D O + m 2 ? D M ) ? ? ? ln ? ? p ? ( O 2 ) < 5 · 10 - 13 ? cm 2 ? / ? s wherein p(O2)in, p(O2)ex, DM, and DO are as defined herein.

Abstract: The invention refers to a process for the formation of a thermal barrier coating on a substrate, comprising the steps of: a) applying a bond coat on the substrate; b) subjecting the bond coat to a low activity aluminizing process, thus obtaining, above the bond coat, a temporary intermediate diffusion layer; c) applying, on the temporary intermediate diffusion layer, aluminium powder in suspension with a solvent or aqueous base, said aluminium powder having size distribution from 15 to 150 ?m; d) performing a thermal treatment in a vacuum at a pressure from 10?3 to 10?5 bars, at a temperature from 800° C. to 1050° C. and with an active phase having duration in the range of 60 minutes to 4 hours, thus obtaining above the bond coat an enriched intermediate diffusion layer; and e) applying a definitive barrier layer on said enriched intermediate diffusion layer.

Abstract: Coating systems and processes by which the coating systems can be deposited to be resistant to contaminants, and particularly resistant to infiltration and damage caused by CMAS. The coating systems include inner and outer ceramic layers, each having a microstructure characterized by splats and horizontal porosity. The inner ceramic layer consists essentially of zirconia stabilized by about 6 to about 9 weight percent yttria. The outer ceramic layer overlies and contacts the inner ceramic layer to define the outermost surface of the coating system. The outer ceramic layer consists essentially of zirconia stabilized by about 25 to about 75 weight percent yttria, has a thickness that is less than the thickness of the inner ceramic layer, and has a porosity level that is lower than that of the inner ceramic layer.

Abstract: A multi-layer coating for protection of metals and alloys against oxidation at high temperatures is provided. The invention utilizes a multi-layer ceramic coating on metals or alloys for increased oxidation-resistance, comprising at least two layers, wherein the first layer (3) and the second layer (4) both comprise an oxide, and wherein the first layer (3) has a tracer diffusion coefficient for cations Mm+, where M is the scale forming element of the alloy, and the second layer (4) has a tracer diffusion coefficient for oxygen ions O2? satisfying the following formula: ? ln ? ? p ? ( O 2 ) in ln ? ? p ? ( O 2 ) ex ? ( D O + m 2 ? D M ) ? ? ? ln ? ? p ? ( O 2 ) < 5 · 10 - 13 ? ? cm 2 / s wherein p(O2)in, p(O2)ex, DM and DO are as defined herein.

Abstract: Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability include providing a component, applying an environmental barrier coating to the component, where the environmental barrier coating includes a CMAS mitigation composition selected from the group consisting of zinc aluminate spinel, alkaline earth zirconates, alkaline earth hafnates, rare earth gallates, beryl, and combinations thereof.

Abstract: A high strength composite particle comprised of a series of incrementally applied resin microlayer coatings such that each of the microlayer partial coatings are interleaved with each other is described. Methods of making the composite particles, as well as methods of using such particles as a proppant in oil and gas well hydraulic fracturing are also described.

Abstract: A method of making a multilayer environmental barrier coating for a ceramic matrix composite is provided, comprising the steps of: plasma spray coating an oxide-based bond coat over top of the ceramic matrix composite and depositing a columnar top coat over the oxide-based bond coat.

Abstract: A method of making a multilayer environmental barrier coating for a ceramic matrix composite is provided, comprising the steps of: plasma spray coating an oxide-based bond coat over top of the ceramic matrix composite and depositing a columnar top coat over the oxide-based bond coat.

Abstract: The invention relates to a device delivering filaments of molten material, especially glass, by Joule heating using a power supply, comprising side plates, a bottom plate provided with nozzles for the flow of the molten material and optionally an upper screen, is characterized in that at least one of these parts capable of being in contact with the molten material is formed by: a solid part made of iron-based alloy having a melting point above 1450° C. that forms a substrate, a metal tie layer formed on at least one portion of the surface of the substrate, a ceramic layer covering the metal tie layer, the metal layer and the ceramic layer forming a diffusion barrier to the components of the alloy that forms the substrate, and a protective coating layer made of platinum or platinum alloy, deposited directly on the ceramic layer.

Abstract: A method for the photocatalytically active coating of surfaces is presented and described, as well as an article (1) photocatalytically actively coated according to this method. The object of providing a method for the photocatalytically active coating of, in particular, metallic surfaces, whereby a permanently stable coating is produced without negatively affecting the photocatalytic activity of the layer, is achieved by a method, in which a substrate article is prepared which has a surface, a metallic adhesion-promoting layer is applied to the surface of the substrate article, a photocatalytically active layer consisting of one or more metal oxides is applied to the adhesion-promoting layer, wherein the metallic adhesion-promoting layer and the surface of the substrate article consist of a different material and the adhesion-promoting layer is selected such that it is not oxidized or reduced by the photocatalytically active layer.

Abstract: A composition based on a novel MCrAlY formulation is provided for the production of protective coatings. The specific combination of the constituents of the MCrAlY formulation advantageously allows significantly high loadings of ceramic (metal oxide) while still retaining the ability to selectively oxidize aluminum to form alumina scale, a property previously not attainable with conventional MCrAlY materials when loaded with ceramics at levels of 15-45 weight percent. The alumina scale in combination with the modified MCrAlY formulation act as a barrier to specific detrimental oxide formations. The compositions of the present invention can act as protective coatings for a wide array of applications.

Abstract: An apparatus for applying segmented ceramic coatings includes means for supporting and moving one or more substrates; one or more heat sources disposed proximate to one or more substrates, wherein at least one of the heat sources is positioned to apply a heat stream to pre-heat a thermal gradient zone on a surface of a substrate; a material deposition device disposed proximate to one or more heat sources, wherein the material deposition device is positioned to deposit a material on a deposition area located behind the thermal gradient zone on the surface; and means for monitoring a surface temperature of one or more substrates.

Abstract: A ceramic thermal barrier coating having improved erosion resistance includes a metallic layer and a ceramic layer positioned on the metallic layer. The ceramic layer includes a first powder, a second powder, and a third powder. The first powder and the second powder are alloyed together prior to being mixed with the third powder.

Abstract: A cooking utensil and a manufacturing method thereof are provided. The cooking utensil includes a cooking body, a first metal-ceramic composite layer having an electromagnetic property and a second metal-ceramic composite layer having a heat conductive property. The cooking body has an external bottom surface. The first metal-ceramic composite layer is disposed on the external bottom surface of the cooking body. The second metal-ceramic composite layer is disposed on the first metal-ceramic composite layer. The cooking utensil is suitable for both an induction cooker and a gas burner.

Abstract: A method for applying a protective layer resistant to high-temperature degradation by corrosion and erosion to a base metal, comprises: applying a MCrAlY-based bond layer to the base metal; coating, by overaluminizing with an Al diffusion layer, the bond layer; subjecting the Al diffusion layer (14) to abrasion treatment so that an outer build-up layer is removed from the Al diffusion layer; and applying a ceramic thermal barrier coating of yttria partially stabilized zirconia to the remaining Al diffusion layer. The ceramic thermal barrier coating is applied to the remaining Al diffusion layer by air plasma spraying. The applied bond layer is subjected to a polishing treatment before being overaluminized such that a surface roughness of Ra?2 ?m is produced at the bond layer.

Abstract: A coating for a metal surface that provides excellent resistance to both electrochemical corrosion and mechanical insult is provided. The coating involves at least an inner coating that is a sacrificial anodic layer and an outer coating that is a protective dielectric material made of inorganic metal oxide. Some versions of the coating include an intermediate layer as well that serves to improve adhesion between the coatings and may provide additional galvanic protection. Although the coating can be made by a variety of methods, advanced methods of spray application are provided for making high-quality lightweight versions the coating.

Abstract: Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability involving providing a component; applying an environmental barrier coating to the component, the environmental barrier coating having a separate CMAS mitigation layer including a CMAS mitigation composition selected from rare earth elements, rare earth oxides, zirconia, hafnia partially or fully stabilized with alkaline earth or rare earth elements, zirconia partially or fully stabilized with alkaline earth or rare earth elements, magnesium oxide, cordierite, aluminum phosphate, magnesium silicate, and combinations thereof.

Abstract: A seal (48) between a compressor rotor blade (26) and compressor casing (28) comprises an abradable structure (59) on the compressor casing (28). The abradable structure (59) comprises a metallic foam (60) having pores (66, 68). The metallic foam (60) has a first a region (62) and a second region (64). The first region (62) of the metallic foam (60) is arranged adjacent to the compressor casing (28) and the second region (64) of the metallic foam (60) is spaced from the compressor casing (28) by the first region (62) of the metallic foam (60). The pores (68) of the second region (64) of the metallic foam (60) contain an abradable material (70) and the pores (66) of the first region (62) of the metallic foam (60) do not contain an abradable material.

Abstract: The invention is directed to an ion plasma deposition (IPD) method adapted to coat polymer surfaces with highly adherent antimicrobial films. A controlled ion plasma deposition (IPD) process is used to coat a metal or polymer with a selected metal/metal oxide. Exposing the coated surface to ultraviolet light significantly improves the antimicrobial properties of the deposited coatings.

Abstract: A thermal spraying method includes forming a coating layer of heat resistant resin on the whole spray area of the metal surface, securely fixing a test piece of the same material as that of the metal as a constituent of heat resistant equipment on the surface of the coating layer, spraying a heat shield coating material onto the test piece, detaching the test piece from the surface of the coating layer, inspecting the condition of spray and setting spray conditions, removing the coating layer and, under the above set spray conditions, spraying the heat shield coating material onto the metal surface to thereby form a heat shield coating layer.

Abstract: Disclosed are a thermal spray coating material which greatly improves corrosion resistance, as compared to conventional Al2O3 and Y2O3 crystalline coatings and Al—Y—O and Al—Zr—O amorphous thermal spray coatings, a production method of the coating material, and a coating method using the same. The thermal spray coating material has a chemical formula of Y2xZr1-xOx+2, where x ranges from 0.19 to 0.83, preferably from 0.35 to 0.69. Accordingly, it is possible to produce a coating material for use in a chamber of vacuum plasmas equipment or internal parts of the chamber can be produced, which improves the corrosion resistance of a protective coating film upon ceramic thermal spray coating and lengthens the lifespan of parts.

Abstract: A tubine engine component has a substrate, a thermal barrier layer deposited onto the substrate, and a sealing layer of ceramic material deposited on an outer surface of the thermal barrier layer for limiting molten sand penetration. The thermal barrier layer and sealing layer are formed by suspension plasma spraying. A preferred sealing layer is gadolinium zirconate.

Abstract: A process of coating an article includes the steps of (1) forming a layer of a ceramic based compound on an article; (2) providing a solution containing a metal as a particulate having a diameter of about 10 nanometers to about 1000 nanometers and present in an amount of about 25 percent to about 50 percent by volume of the solution; (3) contacting the ceramic based compound layer with the solution; (4) drying the article; and (5) optionally repeating steps (3) and (4).

Abstract: In a method for coating a substrate, a ceramic first layer is suspension plasma sprayed and is at least about as tough as 7YSZ. A ceramic second layer is applied over the first layer and is less tough than the first layer.

Abstract: Coated crucibles for holding molten material are disclosed. In some embodiments, the crucibles are used to prepare multicrystalline silicon ingots by a directional solidification process. Methods for preparing such crucibles and methods for preparing silicon ingots by use of such crucibles are also disclosed.

Abstract: A composite body that is spall resistant and comprises a substantially discontinuous cermet phase in a substantially continuous metal rich matrix phase. The composite body is typically bonded to a substrate to form a hardfacing on the substrate. The composite body exhibits ductile phase toughening with a strain to failure of at least about 2 percent, a modulus of elasticity of less than about 46 million pounds per square inch, and a density of less than about 7 grams per cubic centimeter. The metal rich matrix phase between the ceramic rich regions in the composite body has an average minimum span of about 0.5 to 8 microns to allow ductility in the composite body. The composite body has a Vicker's hardness number of greater than approximately 650. The discontinuous cermet phase is in the form of ceramic rich regions embedded within the composite body, and it includes ceramic particles and a cermet binder. The ceramic particles having a Moh's hardness of at least approximately 7.

Abstract: Embodiments relate to a coated substrate and a method of making and using the same. A plasma-spray coated layer may be formed on a substrate, wherein the plasma-sprayed coated layer comprises a rare-earth oxide (e.g., yttrium oxide), a rare-earth fluoride (e.g. yttrium fluoride), or a rare-earth silicate (e.g. yttrium silicate). An exposed surface of the plasma-spray coated layer may be irradiated to form a treated portion of the layer, wherein the treated portion of the layer has a mean spacing of local peaks (S value) between about 100 and 200 microns. A second layer may be formed on the treated portion of the plasma-spray coated layer, wherein the second layer comprises a dielectric material.

Abstract: An insulation coating method for a metal base comprises a thermal spraying step, an impregnation step, and a beam irradiation step. In the thermal spraying step, a first insulation coating is formed by thermally spraying a first metal oxide to the surface of the metal base. In the impregnation step, pores formed in the surface of the first insulation coating are impregnated with a sol that contains, as a dispersoid, a metal oxide, a hydrate of a metal oxide, or a metal hydroxide. In the beam irradiation step, a second insulation coating that is composed of a second metal oxide is formed by irradiating the first insulation coating and the sol with a high energy beam after the impregnation step.

Abstract: Methods and apparatus for thermal barrier coatings are provided. The thermal barrier coating system includes a bond coat, a first thermal barrier coating comprising a thermal conductivity, kA having a first value, and a second thermal barrier coating including a thermal conductivity, kB having a second value wherein the second value is different than the first value.

Abstract: A plasma spray gun comprises a nozzle, an upstream powder injector, and a downstream powder injector. The upstream powder injector is disposed outside the nozzle and axially adjacent a nozzle outlet. The downstream powder injector is disposed axially downstream of the first upstream powder injector. The downstream powder injector is operative in a first coating mode, and the upstream powder injector is operative in a second coating mode.

Abstract: Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability including providing a component; applying an environmental barrier coating to the component, the environmental barrier coating having a separate CMAS mitigation layer including a CMAS mitigation composition selected from the group consisting of zinc aluminate spinel, alkaline earth zirconates, alkaline earth hafnates, rare earth gallates, beryl, and combinations thereof.

Abstract: A wafer has a rare earth oxide layer disposed, typically sprayed, on a substrate. It is useful as a dummy wafer in a plasma etching or deposition system.

Abstract: To manufacture a thermal barrier coating structure on a substrate surface, a working chamber having a plasma torch is provided, a plasma jet is generated in that a plasma gas is conducted through the plasma torch and is heated therein by means of electric gas discharge, electromagnetic induction or microwaves, and the plasma jet is directed to the surface of a substrate introduced into the working chamber. To manufacture the thermal barrier coating, a voltage is additionally applied between the plasma torch and the substrate to generate an arc between the plasma torch and the substrate and the substrate surface is cleaned by means of the light arc, wherein the substrate remains in the working chamber after the arc cleaning and an oxide layer is generated on the cleaned substrate surface and a thermal barrier coating is applied by means of a plasma spray process.

Abstract: This invention relates to a method for preparing a bimetallic titania-based catalyst for use in hydrodesulfurization reactions.

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