Abstract: Forming and depositing a high temperature inorganic coating on a polymeric composite substrate surfaces having deposited thereon an interlayer, and articles produce therefrom. Methods of providing functional properties to said composites are also disclosed.

Abstract: Methods of building Z-graded radiation shielding and covers. In one aspect, the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the methods include improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade from the enclosure.

Abstract: During engine operation, valve retainers and valve springs are constantly rubbing and impacting each other resulting in heat and wear. The purpose of this invention is to provide a surface coating onto the valve retainer to reduce the friction with the valve spring and thus improve durability. Specifically, this invention teaches a method to thermally apply coatings to the surface of the valve retainer. Although typically fabricated from steel, the usage of lighter weight titanium valve retainers is increasing for high performance, or racing engines. The reduced mass allows valves to move more readily and requires less spring pressure to operate, producing more power and a faster revving engine, however titanium is typically not as wear resistant as the steel it replaces. In one embodiment, a porous molybdenum or other oleophilic metal is applied to the surface of the valve retainer. In another embodiment, hard coatings of cermets, carbides, and super alloys are applied as coatings to valve retainers.

Abstract: A method of depositing a carbon particle-containing film that contains carbon particles includes: manufacturing film deposition slurry by mixing liquid into film deposition powder that contains carbon powder formed of the carbon particles; and depositing the carbon particle-containing film by spraying the film deposition slurry to a surface of a base material so that the liquid is vaporized.

Abstract: Disclosed is a method of coating a substrate with a bulk-solidifying amorphous alloy using a thermal spraying technique to provide a coating that is substantially amorphous. Some embodiments include using a substrate having a thickness greater than the critical casting thickness of the bulk-solidifying amorphous alloy, and using a brazing material to assist in adhering the coating to the surface.

Abstract: Various embodiments provide materials, parts, and methods useful for electronic devices. One embodiment includes providing a coating on at least one surface of a substrate, increasing an amorphicity of the coating, and incorporating the substrate including the coating having increased amorphicity into an electronic device. Another embodiment relates to frictionally transforming a coating from crystalline into amorphous to form a metamorphically transformed coating for an electronic device. Another embodiment relates to an electronic device part having a metamorphically transformed coating disposed on at least one surface thereof.

Abstract: The invention relates to a bearing part as well as to a spray method for manufacturing a layer system on a bearing part, in particular a connecting rod eye of a connecting rod for a reciprocating piston combustion engine, with a layer system containing at least tin being provided on a surface of the bearing part. In accordance with the invention, an outer, thermally sprayed top layer of the layer system is composed only of tin with the exception of contaminants.

Abstract: A metal customization process that provides an alloy metal product which meets predefined product specifications which are typically based on whole thickness materials. The metal customization process can be used with any commercially available substrates (e.g., aluminum bar, aluminum coil, steel bar, steel coil, and alloys thereof) but, preferably, the substrate is made of steel (e.g., carbon steel, low carbon steel or steel alloys). This process can include receiving a product specification that can include performance or composition criteria; converting the product specification to a surface specification and a core specification; then treating a substrate with a deposition composition, for example, at a temperature below an annealing temperature, thereby depositing at least one alloying element onto the substrate to form a coating composition that is carried by the substrate; and then annealing the coated substrate to provide a product that meets the product specification.

Abstract: An aluminum alloy component has a surface region alloyed with an anodic metal to increase corrosion resistance in aqueous environments with high salinity or sulfur content.

Abstract: A zirconium alloy for use in nuclear fuel assemblies is provided, which provides increased resistance against oxidation and corrosion and also improved bonding with parent material, because pure metallic material such as silicon (Si) or chromium (Cr) is evenly coated on the surface of the parent material by plasma spraying. Because the plasma spray coating used to coat the pure metallic material on the zirconium alloy does not require vacuum equipment and also is not limited due to the shape of the coated product, this is particularly useful when evenly treating the surface of the component such as 4 m-long tube or spacer grip arrangement which is very complicated in shape. Furthermore, because the coated zirconium alloy confers excellent resistance to oxidation and corrosion under emergency such as accident as well as normal service condition, both the economic and safety aspects of nuclear fuel are improved.

Abstract: A method of forming a corrosion resistant neutron absorbing coating comprising the steps of spray or deposition or sputtering or welding processing to form a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material. Also a corrosion resistant neutron absorbing coating comprising a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material.

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: A package for fruits and vegetables having galvanic functionality is formed by using two or more metals with different galvanic activity properties on the surface of a nonmetallic substrate. The metals may be deposited electrolytically, by vacuum, autocatalytically, or by other methods. The metals are selected to create a galvanic reaction after the package is filled with a low pH food product and its associated liquids, juices, brine, etc. The package may extend the shelf-life of the food product contained therein, for example, by making metal ions available to the food product.

Abstract: A system for in-process orientation of particles used in direct-write inks for fabricating a component may include a device for polarizing direct-write particles in an aerosol. An outlet may direct the aerosol including the polarized direct-write particles on a substrate to form a component. An apparatus may cause the polarized direct-write particles to be aligned in a selected orientation to form the component with predetermined characteristics when deposited on the substrate.

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: A substrate for depositing diamond by CVD, comprising a base body of hard material and a coating layer that holds diamond particles as seed crystal in a matrix and is deposited joined thereto on a surface of said base body, wherein: the seed diamond particles have an average particle size of 1 ?m or smaller; the matrix comprises a first metal selected from a first group of Si, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W and/or a first compound between said first metal and a non-metallic substance selected from boron, carbon and nitrogen, said matrix holding the diamond particles distributed therein; and a joint zone developed as a result of a diffusion process and extending over said base body and coating layer comprises either or both atoms of said first metal and a component metal of the hard material.

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 bogie shaft for railway vehicles has a cladding which contains a metal component. The metal component is preferably electrochemically less refined, but no greater than exactly as refined, as a material of the bogie shaft. Corrosion on the bogie shaft can thereby be advantageously prevented. The metal material of the cladding is also able to effectively protect the bogie shaft against stone impact. The cladding can be advantageously applied by cold gas spraying, or a sleeve can be bent around the bogie shaft for forming the cladding. The cladding can advantageously contain particles that can make it more resistant to stone impact. The particles can be made, for example, of hard materials, of particularly ductile particles, or of particles made of a memory shape alloy.

Abstract: An aluminum alloy component has a surface region alloyed with an anodic metal to increase corrosion resistance in aqueous environments with high salinity or sulfur content.

Abstract: An aluminum alloy component has a surface region alloyed with an anodic metal to increase corrosion resistance in aqueous environments with high salinity or sulfur content.

Abstract: A process of fabricating a thermal barrier coating is disclosed. The process includes cold spraying a substrate with a feedstock to form a thermal barrier coating and concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating. The cold spraying is in a region having an oxygen concentration of at least 10%. In another embodiment, the process includes heating a feedstock with a laser and cold spraying a substrate with the feedstock to form a thermal barrier coating. At least a portion of the feedstock is retained in the thermal barrier coating. In another embodiment, the process of fabricating a thermal barrier coating includes heating a substrate with a laser and cold spraying the substrate with a feedstock to form a thermal barrier coating.

Abstract: A gate valve has a body, the body having a cavity and a flow passage intersecting the cavity. A seat ring is mounted to the body at the intersection of the flow passage and the cavity, the seat ring having an engaging face. A gate in the cavity has an engaging face that slidingly engages the face of the seat ring while being moved between open and closed positions. A friction-resistant coating is on at least one of the faces.

Abstract: A thermal spraying method is provided, wherein spray particles of a powdered spray material are introduced into a hot carrier gas stream, heated by the carrier gas stream and then sprayed onto the surface of a substrate by a spray nozzle, wherein the temperature of the spray particles upon impact onto the substrate is below the melting temperature of the spray material. The spray particles are heated in the hot carrier gas stream upstream of the nozzle throat to a temperature that causes at least partial melting of the spray particles in that location.

Abstract: An apparatus and methods for cold spraying with a spraying unit, a particle supply, a gas supply, and at least one heating unit. The heating unit contains a graphite felt that can be heated with an electric heater current, through which a gas stream can flow, wherein the at least one heating unit is arranged separately and/or in a pressure tank through which the gas stream can flow.

Abstract: Refractory metal powders are dehydrided in a device which includes a preheat chamber for retaining the metal powder fully heated in a hot zone to allow diffusion of hydrogen out of the powder. The powder is cooled in a cooling chamber for a residence time sufficiently short to prevent re-absorbtion of the hydrogen by the powder. The powder is consolidated by impact on a substrate at the exit of the cooling chamber to build a deposit in solid dense form on the substrate.

Abstract: Briefly, in one embodiment, a method is disclosed. The method includes introducing a powder feedstock into a cold-spray apparatus, and operating the cold-spray apparatus to deposit the feedstock. The feedstock includes particles including nickel-base alloy having a thermally altered microstructure.

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: A coated article system includes a substrate and a surface coating on the substrate. The surface coating is formed by depositing individual particles of a composite metal powder with sufficient energy to cause the composite metal powder to bond with the substrate and form the surface coating. The composite metal powder includes a substantially homogeneous dispersion of molybdenum and molybdenum disulfide sub-particles that are fused together to form the individual particles of the composite metal powder.

Abstract: A mirror or mirror assembly fabricated by molding, pressing, assembling, or depositing one or more bulk metal glass (BMG), bulk metal glass composite (BMGMC), or amorphous metal (AM) parts and where the optical surface and backing of the mirror can be fabricated without machining or polishing by utilizing the unique molding capabilities of this class of materials.

Abstract: A torch introduces oxidizer into a passage so as to swirl the oxidizer about a central axis, while fuel is introduced at a location spaced apart from the central axis, where the swirling action of the oxidizer is strong, resulting in rapid mixing of the fuel and oxidizer. In practicing the method, the length of a bore through which the fuel and oxidizer pass is maintained short enough that a sheath of unmixed oxidizer surrounds the combusting mixed fuel and oxidizer, eliminating any need for water cooling. The lengths of torches of the present invention can be significantly shorter than those of the prior art, making the torches well suited for use in confined spaces, and the torches have been found to allow spraying materials at a greater rate than torches of the prior art. The reduced length also facilitates introducing into the passage material to be spray-coated.

Abstract: A device comprises a metal plate (4) and an element (2) for supporting the plate (4), wherein a portion (5) of the plate (4) is wrapped around the supporting element (2), wherein the plate (4) is coated with a sol-gel coating having a thickness which is in a range of 25 to 60 micrometers. In a manufacturing process of the device, the metal plate (4) is attached to the supporting element (2) by subjecting at least a portion (5) of the plate (4) to a process of mechanical deformation, wherein the sol-gel coating is applied to the plate (4) prior to attaching the plate (4) to the supporting element (2). Tests have proven that it is possible to have both the relatively thick coating and the mechanical deformation of at least a portion (5) of the plate (4) to which the coating is applied, without the formation of cracks in the coating.

Abstract: A method and apparatus for forming an electrochemical layer of a thin film battery is provided. A precursor mixture comprising precursor particles dispersed in a carrying medium is activated in an activation chamber by application of an electric field to ionize at least a portion of the precursor mixture. The activated precursor mixture is then mixed with a combustible gas mixture to add thermal energy to the precursor particles, converting them to nanocrystals, which deposit on a substrate. A second precursor may be blended with the nanocrystals as they deposit on the surface to enhance adhesion and conductivity.

Abstract: This invention relates generally to articles, devices, and methods for controlling the impingement behavior of molten metal/ceramic droplets on surfaces in industrial processes. The texture of a substrate surface is engineered such that impinging molten metal droplets actually bounce off the surface. Likewise, the texture of a substrate surface can be engineered such that impinging molten metal droplets stick to the surface.

Abstract: One aspect of the present invention includes a method. The method includes combusting a fuel and an oxidant in a combustion chamber of a thermal spray gun to form a combustion stream. The method further includes injecting a liquid and a feedstock material into the combustion stream in the combustion chamber to form an entrained feedstock stream, wherein the feedstock material includes a plurality of cermet particles having a median particle size of less than about 5 microns. The method further includes directing the entrained feedstock stream on a surface of a substrate to form a coating, wherein a temperature of the plurality of cermet particles in the entrained feedstock stream is less than a melting temperature of the plurality of cermet particles. Coated articles are also presented.

Abstract: Provided are a pre-treatment apparatus and method for improving an adhesion of a thin film The pre-treatment apparatus includes: a gas compressor that compresses gas supplied from the outside and contained, and supplies a process gas that is compressed; a powder feeder for supplying a coating powder including a single metal or alloy supplied from the outside and contained; and a spray nozzle through which the process gas supplied from the gas compressor and the coating powder supplied from the powder feeder are cold sprayed on a surface of a base metal on which a thin film is to be deposited so as to form a porous metal coating layer on the surface of the base metal.

Abstract: An electromagnetic shielding article includes a plastic substrate; a nickel vanadium layer deposited on the plastic substrate; an electromagnetic shielding layer deposited on the plastic substrate; and a protection layer deposited on the electromagnetic shielding layer. A method for manufacturing the electromagnetic shielding article comprising steps of: providing a plastic substrate; depositing a nickel vanadium layer on the plastic substrate by radio-frequency induction plasma spraying process; depositing an electromagnetic shielding layer on the nickel vanadium layer; and depositing a protection layer on the electromagnetic shielding layer.

Abstract: A method for making a multilayer coating on a surface of a substrate by means of at least one thermal spraying method, wherein the following successive steps are carried out: a) a first nanostructured or finely structured layer (21) of a first material is deposited on the surface of the substrate (20) by means of a thermal spraying method via a liquid route; the surface of the substrate (20) not having been subject, prior to the deposition of the first nanostructured or finely structured layer (21), to any preparation or activation treatment other than an optional cleaning treatment; b) a second microstructured layer (22) of a second material is deposited on the first nanostructured or finely structured layer (21) by means of a thermal spraying method. The first layer obtained in step a) is an adhesion layer aiming at optimizing the adhesion of the layer obtained in step b) without any surface preparation or activation.

Abstract: A coated article system includes a substrate and a surface coating on the substrate. The surface coating is formed by depositing individual particles of a composite metal powder with sufficient energy to cause the composite metal powder to bond with the substrate and form the surface coating. The composite metal powder includes a substantially homogeneous dispersion of molybdenum and molybdenum disulfide sub-particles that are fused together to form the individual particles of the composite metal powder.

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 method and system for depositing multiple materials onto a substrate is described. The method broadly comprises the steps of providing a source of a first powder material to be deposited, providing a source of a second powder material to be deposited, and sequentially depositing the first powder material and the second powder material onto the substrate at a velocity sufficient to deposit the materials by plastically deforming the materials without metallurgically transforming the particles of powder forming the materials.

Abstract: A thermal spray powder contains granulated and sintered particles composed of an oxide of any of the rare earth elements having an atomic number from 60 to 70. The average particle size of the primary particles constituting the granulated and sintered particles is 2 to 10 ?m. The crushing strength of the granulated and sintered particles is 7 to 50 MPa. A plasma resistant member includes a substrate and a thermal spray coating provided on the surface of the substrate. The thermal spray coating is formed by thermal spraying, preferably plasma thermal spraying, the thermal spray powder.

Abstract: A method for repairing a component such as a turbine blade is provided. At the end of its operating time, the component has, for example, a depletion of aluminium in a region near the surface. The application of a repair layer is provided including particles with an increased proportion of aluminium. A subsequent heat treatment may achieve the effect of equalizing the concentration of aluminium between the repair layer and the region near the surface, and so the aluminium content required for new components is achieved again.

Abstract: In a method of manufacturing a wiring board, a basic circuit pattern is formed on an insulating plate, and a metal layer is formed on the basic circuit pattern by cold spraying to thereby form a built-up circuit pattern on the basic circuit pattern.

Abstract: The invention relates to a coating for a device for forming glass products, comprising: a first quasicrystalline or approximant or amorphous metallic phase; and a second phase composed of a eutectic alloy having a melting point between 950 and 1150° C. and having a nominal hardness between 30 and 65 HRc; a mould for manufacturing hollow glass products that is provided with this coating; equipment for forming glass in sheets or plates that is provided with this coating; a material constituting this coating; a premixed or prealloyed powder, or a flexible cord or cored-wire that makes it possible to obtain this coating; a thermal spraying process for obtaining this coating.

Abstract: The invention is directed to an antimicrobial metal composite formed by vaporizing an antimicrobial metal or antimicrobial metal salt such as silver, copper or salts thereof using an plasma system and cooling the formed vapor in the presence of a fluidized gas of filler powder. Alternatively, the filler or a filler precursor is entrained with the antimicrobial metal or antimicrobial metal precursor and vaporized and then upon cooling the antimicrobial metal vapor and filler vapor condense to form the composite. The composite shows high antimicrobial activity and can be incorporated into or onto polymers, coatings, textiles, paper, gels (for example for wound care), lubricants, adhesives and cosmetics or pharmaceutical, especially medical devices.

Abstract: Disclosed are a plasma nano-powder synthesizing and coating device and method, the device comprising: a chamber which forms a sealed space, and comprises a reaction unit provided at one side and a processing unit provided at the other side, the reaction unit provided in an upstream of gas flowing in the chamber, having a high-temperature plasma region formed by a plasma torch generating plasma with an applied electric current, and comprising a mixed gas feeder to supply mixed gas to the reaction unit and a powder feeder to supply powder to the reaction unit, and the processing unit provided in a downstream of plasma flame in the chamber, and comprising a supporter to support a material; and a vacuum forming unit which forms a vacuum inside the chamber, the powder being supplied to the reaction unit and reacting in the plasma region of the reaction unit, and the reacted powder being synthesized in the reaction unit, the processing unit and a surface of the supporter, and coated on a surface of the material of

Abstract: A method for forming an oxide-dispersion strengthened coating on a metal substrate is disclosed. The method generally includes comminuting MCrAlY alloy particles to form an oxygen-enriched powder, wherein at least about 25% by volume of the MCrAlY alloy particles within the oxygen-enriched powder have a particle size of less than about 5 ?m. Additionally, the method includes applying the oxygen-enriched powder to the metal substrate to form a coating and heating the oxygen-enriched powder to precipitate oxide dispersoids within the coating.

Abstract: A running-in coating for gas turbines and a method for production of a running-in coating are provided. The running-in coating serves to seal a radial gap between a housing (11) of the gas turbine and the rotating blades (10) themselves, whereby the running-in coating (13) is applied to the housing. The running-in coating is made from a CoNiCrAIY-hBN material. The CoNiCrAIY-hBN material can be applied by thermal spraying, in particular plasma spraying.

Abstract: Methods of the invention allow rapid production of high-porous, large-surface-area nanostructured metal and/or metal oxide at attractive low cost applicable to a wide variety of commercial applications such as sensors, catalysts and photovoltaics.

Abstract: A bi-laterally surfaced substrate in which the first surface consists of one or more than one of cerium oxide, aluminum oxide, tin oxide manganese oxide, copper oxide, cobalt oxide, nickel oxide, praseodymium oxide, terbium oxide, ruthenium, rhodium, palladium, silver, iridium, platinum and gold and the second surface consists of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold and micro channel micro component reactors including such substrates in a predetermined formed shape and methods for making the same utilizing a thermal spray on one side and a physical deposition process on the other side.