Abstract: A thermally sprayed article and method of making same includes the steps of providing an article to be thermally sprayed and thermally spraying a metal material against the article to form an inner layer having a first predetermined thickness. The method also includes the steps of co-depositing a polymer and the metal material against the inner layer to form an outer layer having a second predetermined thickness.

Abstract: A mixed powder thermal spraying method in which:

Abstract: Multi-layer corrosion resistant polymer composite coatings are described wherein a first coating layer is applied by high velocity high temperature spray, thermal spray, plasma spray, fluidized bed, hot melt or electrostatic spray onto an unprepared, particle embedded or alternatively prepared substrate, and the outer surface of the still warm first layer is roughened by embedding particles therein or the outer surface is roughened mechanically, and a second coating layer is applied thereover. Filler powder may be added to one or both of the layers to substantially match the thermal expansion coefficients of the two layers.

Abstract: A roughened bond coat comprises a screen that includes interwoven wires defining openings and a metallic material disposed on the screen. The screen and metallic material form a roughened bond coat possessing an uneven, undulated, and irregular surface. The metallic material may be one of a slurry and a powder, and applied by coating and spraying, respectively. A thermal barrier coating system, which is formed with and incorporates the roughened bond coat, exhibits greater adhesion of a thermal barrier coating and bond coat due to an increased interfacial surface area provided by the uneven, undulated, and irregular surface.

Abstract: An article includes a substrate and an adhesion layer overlying the substrate. The adhesion layer includes a first phase including particles, and a second phase including braze alloy that bonds the particles to the substrate. The article further includes a ceramic layer overlying the adhesion layer. In one embodiment, the ceramic layer is a thermal barrier coating (TBC), formed of stabilized zirconia (ZrO2).

Abstract: A method of providing a roughened bond coat, for example in a thermal barrier coating system, comprises providing an oxidation-resistant plasma-sprayed layer onto a substrate and disposing a slurry overlayer on the oxidation-resistant plasma-sprayed layer. These steps form a roughened bond coat possessing an uneven, undulated, and irregular surface. A roughened bond coat in a thermal barrier coating system reduces de-bonding of the bond coat and a thermal barrier coating layer, which is desirable to maintain the insulation features of the thermal barrier coating system.

Abstract: A method of coating an inner surface of a weapon barrel includes the following steps: introducing a plasma burner into the weapon barrel; producing a plasma flame by the plasma burner; directing the plasma flame against the inner barrel surface to cause impingement thereon; introducing a coating material in powder, wire or ribbon form into the plasma flame for melting the coating material to form a molten liquid and for depositing the molten liquid by the plasma flame on the inner barrel surface; and moving the plasma burner inside the weapon barrel axially thereof and relative thereto while performing the depositing step for obtaining a surface coating on the inner barrel surface.

Abstract: In order to produce connecting rod bearings which are easier to mount and which are the larger strongly bonded, the large connecting rod eye is plasma-coated with an aluminum-bronze. At the start of the plasma-spraying process, the plasma layer is deposited at a high temperature in order to ensure that the plasma layer bonds well to the connecting rod eye material and has a low level of porosity. In order to prevent the connecting rod eye material from annealing, the depositing temperature of the plasma layer is reduced so that the material to be removed during subsequent finishing is deposited at a lower temperature. After the plasma-coating process is complete, the connecting rod eye is opened by taking off the bearing cover, thus breaking the plasma layer. The cover is then remounted and the bearing surface is finished by fine spindling. The bearing layer has an annular groove in order to improve the oil holding volume.

Abstract: A member covered with a self-fluxing alloy sprayed coating is produced by previously forming a porous ceramic sprayed coating on a surface of a self-fluxing alloy sprayed coating prior to a refusing treatment of the coating formed on a substrate, heating the sprayed coating in an inert gas atmosphere controlled to 1˜300 hPa or by a high frequency induction heating system and thereafter removing the ceramic sprayed coating to expose the self-fluxing alloy sprayed coating. This member is uniform in the thickness, less in the retention of pores or oxide impurities and has a strong coating property.

Abstract: A ceramic capacitor having an improved electrode soldering performance, little or no diffusion of solder even in the case of being used under a high temperature environment and a reduced characteristic deterioration is provided. The dry plating electrodes have a three-layer structure. First layers of the electrodes are respectively provided on both surfaces of a ceramic element assembly and made of any one or more of Cu, Ni-Cu alloy and Zn. Second layers of the electrodes are respectively provided on the surfaces of the first layers and made of a material different from the material of the first layers and any one or more of Cr, Ni-Cr alloy, Fe-Cr alloy, Co-Cr alloy, Ti, Zn, Al, W, V and Mo. Third layers of the electrodes are respectively provided on the surfaces of the second layers and made of any one or more of Cu, Ni-Cu alloy, Ag and Au.

Abstract: The present invention is directed to a means for the surface preparation of a metal or metal alloy substrate. In the process of the present invention, a stream of a mixture of flux particles and metal particles is hurled at the substrate at velocities effective for flux adhesion to the surface. The velocities of the particle stream is adjusted so that the flux particles adhere to the surface and the metal particles bounce off the surface. At higher temperatures and velocities, the metal particles are co-deposited with the flux.

Abstract: An integral, lightweight combustion chamber/nozzle assembly for a rocket engine has a refractory metal shell defining a chamber of generally frusto-conical contour. The shell communicates at its smaller end with a rocket body, and terminates at its larger end in a generally contact contour, which is open at its terminus and which serves as a nozzle for the rocket engine. The entire inner surface of the refractory metal shell has a thermal and oxidation barrier layer applied thereto. An ablative silica phenolic insert is bonded to the exposed surface of the thermal and oxidation barrier layer. The ablative phenolic insert provides a chosen inner contour for the combustion chamber and has a taper toward the open terminus of the nozzle. A process for fabricating the integral, lightweight combustion chamber/nozzle assembly is simple and efficient, and results in economy in respect of both resources and time.

Abstract: In order to provide a heat pipe for transporting heat from an evaporation area to a condensation area, comprising a housing with housing walls, a capillary structure arranged in the housing and thermally coupled to the respective, corresponding housing wall in the evaporation area as well as in the condensation area, a vapor channel arranged in the housing and leading from the evaporation area to the condensation area as well as a heat transport medium, as well to make available a process for the production of such a heat pipe it is suggested that the capillary structure be an open-pored capillary layer produced by way of thermal plasma spraying of powder particles.

Abstract: An apparatus and method for performing material deposition on semiconductor devices. The apparatus provides an enclosure for defining a chamber. The chamber includes a metallic portion such as a conductor coil powered by a voltage generator. A gas, having a suspension of particles for treating the semiconductor devices, is introduced into the chamber and the powered conductor coil converts the gas to inductively coupled plasma and vaporizes the particles. The particles can then be deposited on the semiconductor devices.

Abstract: The invention provides a method and an apparatus for thermally coating the cylinder barrels of a cylinder block of a combustion engine. During the coating operation, air flows through the cylinder bore whose barrel is to be coated with a flow velocity of between 7 m/s and 12 m/s. This air flow is generated by means of extraction, whereby the air is extracted from the bottom of the cylinder bore through the crank case of the cylinder block. For extracting the air, a plurality of extraction collars are provided that are connected to an extraction fan and are moved from the bottom through the crankcase to the lower end of the cylinder bores. During the coating operation, the pressure of the air flowing through extraction conduits to the extraction fan is measured and the value of the velocity of the air flow through the cylinder bore is calculated. An adjustment mechanism controls air chokes in the air conduits in response to the calculated flow velocity present in the cylinder bores.

Abstract: A method for protecting a synthesis gas generator burner heat shield includes coating the burner heat shield with an overlay alloy coating composition of the formula MCrAlY wherein M is selected from the group consisting of iron, nickel, and cobalt. In a preferred embodiment, the coating includes from about 20-40 weight % Co, 5-35 weight % Cr, 5-10 weight % Ta, 0.8-10 weight % Al, 0.5-0.8 Y, 1-5 weight % Si and 5-15 weight % Al2O3.

Abstract: A method for producing cylinder linings in an aluminum or magnesium engine block for an internal combustion engine utilizes plasma spraying of a mixture of powdered molybdenum and powdered steel containing from about 10 to about 70 wt. % molybdenum and from about 90 to about 30 wt. % steel. The resulting slide layer has good adhesion to the engine block and has high wear resistance.

Abstract: Embodiments include a method for depositing material onto a workpiece in a sputtering chamber. The method includes sputtering a target and a coil in said sputtering chamber. The coil may have a preformed multilayer structure formed outside of the sputtering chamber. The outer layer of the coil may act as a secondary source of deposition material. The multilayer structure may be formed with an inner region or a base metal and an outer layer of a sputtering metal. The outer layer may be formed using a process such as plasma spraying, arc spraying, flame spraying, ion plating, chemical vapor deposition and electroplating.

Abstract: A method of manufacturing a metal and polymeric composite article by the following steps. Droplets of spray deposited metal and spray deposited polymeric material are combined to form an article having the polymeric material interspersed within the metal. A carrier or form that shaped to receive the metal and polymeric layers is provided. The carrier may be made either stationary or movable. Layers of spray deposited metal and spray deposited polymeric material are applied atop the carrier. The spray deposited metal is between 90 and 95 percent by volume of the article. The polymeric layers do not completely cover the metal layers. Succeeding spray deposited metal layers contact bond to previous metal layers. The polymeric material between imbedded between the interconnected metal layers.

Abstract: A method of producing a nanocomposite coating without gaseous precursor reactants. A non-nanocrystalline particulate containing a polymorphic material in an atmospheric phase is introduced into a high-velocity gas jet. The projected particulate is allowed to impact a substrate at a velocity effective to cause at a least a portion of the polymorphic material to transform to a nanocrystalline, high pressure phase.

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: Methods and apparatus for reducing the TPM level of a diesel engine exhaust stream by providing a suitable oxidation catalyst into the exhaust train. The oxidation catalyst may be incorporated into a thermal insulative coating on the inner surface of the exhaust train, particularly the exhaust manifold and exhaust pipes prior to the turbocharger. Alternatively, when the exhaust train includes a turbocharger, the catalyst can be in a separate monolithic unit between the engine and the turbocharger. The system may also include an improved diesel oxidation catalyst unit having a metal monolithic substrate. The oxidation catalyst can also be incorporated into a thermal insulative coating inside the cylinders, particularly on non-rubbing surfaces such as The invention also includes the use of a protective mullite top coat on the thermal coating. A further embodiment is the use of a stainless steel bond coat to bind the thermal coating to a metallic substrate, particularly an aluminum substrate.

Abstract: A method for applying a porous coating incorporating a tricomponent powder mixture deposited on a hard substrate (i.e. metallic or ceramic) by plasma spraying. The coating has high adhesion strength to the substrate, with outstanding thermo-mechanical characteristics and with good resistane to thermal or mechanical action. The mixure includes aluminum oxide and/or titanium oxide powder and glass powder as the coating's microstructure forming materials; aluminum and/or titanium power metal binder and aluminum hyroxide and/or titanium hydroxide powder as a material assuring the formation of coating's microstructure. Plasma spraying includes passing the powder through the plasma beam, simultaneously melting of the metal oxide, partially alloying components into separate plasma beam zones—the hydroxide to the colder zone, and the metal to the hotter zone. The aluminum particles reach the substrate first and develop the adhesion of the sprayed layer to the substrate.

Abstract: A method for staining a plurality of semiconductor wafers and wafer samples with a chemical. The method includes gripping first and second semiconductor wafers and orienting the second semiconductor wafer such that it is substantially coplanar with the first semiconductor wafer and suspending the first and second semiconductor wafers such that at least portions thereof extend into the chemical. The method may also include gripping a first semiconductor wafer and a second semiconductor wafer that has a different size from the first and suspending first and second semiconductor wafers such that at least portions thereof extend into the chemical.

Abstract: An abrasion resistant coating is created by adding a ductile phase to a brittle matrix phase during spray coating where an Al—Cu—Fe quasicrystalline phase (brittle matrix) and an FeAl intermetallic (ductile phase) are combined. This composite coating produces a coating mostly of quasicrystal phase and an inter-splat layer of the FeAl phase to help reduce porosity and cracking within the coating. Coatings are prepared by plasma spraying unblended and blended quasicrystal and intermetallic powders. The blended powders contain 1, 5, 10 and 20 volume percent of the intermetallic powders. The unblended powders are either 100 volume percent quasicrystalline or 100 volume percent intermetallic; these unblended powders were studied for comparison to the others.

Abstract: A method of preparing a planographic printing member is disclosed. In one embodiment, the method comprises forming a hydrophilic layer by thermally spraying a hydrophilic particulate material onto an ablatable layer. Typical hydrophilic materials are SiO2, Al2O3, Cr2O3, TiO2 and ZrO2. Spraying a plasma containing the hydrophilic material in an inert gas atmosphere is preferred method for forming the hydrophilic layer.

Abstract: The present invention relates to a method for depositing braze alloy on a surface of a component that will be subsequently joined to a second component. In one form a braze alloy is sprayed by a thermal process. The braze alloy is sprayed in such a fashion that substantially all of the powder braze alloy is unmolten, but is heated to a state deformable enough to bond to the surface. One form of the spraying operation utilizes a High Velocity Oxygen Fuel spray gun.

Abstract: The method for improving the corrosion resistance of reinforced concrete coated with a thermal spray coat of metals, especially of zinc or zinc alloys, is effected by electrically connecting said spray coat with the armour and additionally coating it with a polyurethane resin which is applied as a low-viscosity solution in organic solvents.

Abstract: A plant for metallization of a metal pipe obtained by upward vertical continuous casting and displaced vertically in a continuous manner, includes, along the path of the pipe, a metallization station having a passage for the pipe, a metallization enclosure (6), spray guns (11) mounted inside the enclosure on an oscillating plate (10) surrounding the path, means for supplying each gun with metallization material (12), and a device for causing oscillation of the support plate and for displacing the guns inside the enclosure with an oscillating movement, the frequency and angular amplitude of which ensure the formation of a coating of uniform thickness.

Abstract: The present invention relates to a method of soldering a semiconductor chip to a substrate, such as to a capsule in an RF-power transistor, for instance. The semiconductor chip is provided with an adhesion layer consisting of a first material composition. A solderable layer consisting of a second material composition is disposed on this adhesion layer. An antioxidation layer consisting of a third material composition is disposed on said solderable layer. The antioxidation layer is coated with a layer of gold-tin solder. The chip is placed on a solderable capsule surface, via said gold-tin solder. The capsule and chip are exposed to an inert environment to which a reducing gas is delivered and the capsule and chip are subjected to a pressure substantially beneath atmospheric pressure whilst the gold-tin solder is heated to a temperature above its melting point.

Abstract: A micro-circuit for performing analyses of multimolecular interactions and for performing molecular syntheses, comprising: (a) a support; (b) at least one micro-electrode attached to the support, the micro-electrode being selectively electronically activated and the micro-electrode having a protective layer which is removable; (c) a binding entity for attachment to the at least one micro-electrode, the binding entity being capable of attachment to at least one micro-electrode when the protective layer has been removed; and (d) a power source being operatively connected to at least one micro-electrode for electronically activating at least one micro-electrode. The micro-circuit of the present invention also includes embodiments featuring a micro-circuit reader for detecting the interaction of the binding entity to a complementary probe, as well as methods for making and using the micro-circuit of the present invention.

Abstract: A corrosion-resistant and brazeable aluminum material. has an aluminum core, and a thermally sprayed layer formed on the core is composed of a brazing metal intermingled with zinc or its alloy. The brazing metal may be a mixture of aluminum and silicon, an aluminum-silicon alloy, a blend of the mixture with the alloy, or silicon. The brazeable aluminum material may be produced by blending a first powder of the brazing metal with a second powder of a corrosion resistant substance including zinc, so as to prepare a powder mixture, and then thermally spraying the powder mixture onto the aluminum core.

Abstract: The invention relates to a method for applying a coating by means of plasma spraying to a substrate, in which method the beam of a laser is additionally used, it being possible to coat a very wide variety of substrates in order, in particular, to improve the properties on the substrate surface. Moreover, the method according to the invention is to achieve a high coating rate and, in addition to advantageous adhesion and density of the layer, also to influence in a controlled manner the layer structure which is being formed.

Abstract: A variety of new ways can be used for associating antimicrobial elemental metal with a medical article. The associated antimicrobial metal reduces the risk of infection associated with the medical use of the medical article. New medical articles are produced by some of these new approaches. Some of the methods involve ways of adjusting the dissociation rate of associated elemental metal such that desired degrees of antimicrobial activity can be achieved over selected periods of time.

Abstract: This disclosure relates to an Sn-containing and/or Bi-containing zinc alloy for hot galvanizing steel, more particularly for component galvanizing. The alloy is composed of 1 to 5% by weight of Sn+Bi, 0 to saturation of Pb, 0.025 to 0.200% by weight of at least one of Ni, Cr or Mn, 0 to 0.030% by weight of at least one of Al, Ca and Mg, the remainder being zinc and unavoidable impurities.

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 method of bonding a thermally sprayed coating to a non-roughened light metal surface. The method comprises the steps of (a) depositing a coating surface (i.e. a double potassium aluminum fluoride salt) onto such surface which has been cleaned to be substantially free of grease and oils. The aqueous deposition provides a protective coating layer to inhibit oxide growth; and (b) subsequently thermally spraying metallic droplets or particles onto the protective coating surface to form a metallic coating that is metallurgically bonded to the cast surface.

Abstract: In order to advantageously solve problems such as lowering of the productivity, contamination of alloy coating due to the adoption of different metal, increase of the cost due to the adoption of different coating process, a coating of MCrAlX alloy containing an oxide such as CoO, NiO or the like is directly formed at a thickness of 10˜500 &mgr;m through a low pressure plasma spraying process containing substantially no oxide and thereafter the same MCrAlX alloy xontaining no oxide is applied thereonto at a thickness of 100˜800 &mgr;m through a low pressure plasma spraying process in a non-oxidizing atmosphere to form a composite sprayed coating.

Abstract: A method of reducing distortion in a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of building a thermal model of the desired tool from a solid model of the ceramic pattern and applying thermal boundary conditions to the thermal model based on known conditions. The method also includes the steps of running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value. The method further includes thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value.

Abstract: A method of fabrication and inspection includes depositing a coating and determining at least one physical property of the coating using eddy current techniques. In a detailed embodiment an abradable coating having a metal volume fraction in the range of from 0.3 to 0.5 is applied to an inner circumference of a stator for a gas turbine engine compressor. The eddy current probe is positioned by a manipulator. A distance separating the probe and a surface of the coating is measured using a frequency above one megahertz (MHz). The thickness of the coating is measured by determining the rolloff frequency for the coating's complex impedance. The coating density is determined by its complex impedance at a characteristic frequency below four MHz. The density can be used as an indication of the performance of the coating with respect to abradability and the erosion resistance. The measurements may also be applied as a post-process quality control technique.

Abstract: A self-fusing alloy thermal spray coating or a vitreous ceramic coating is fused to a complicated metal shape or convoluted metal surface, such as a waterwall panel having a plurality of tubes interconnected by a plurality of membranes, without significant warpage or adverse change in the microstructure of the material forming the panel. The coating is first applied to the panel and then is heated to a liquidus temperature (typically between about 1000.degree.-2200.degree. F.), by induction at a frequency of greater than about 25 kHz, so as to effect fusing. An inductive coil assembly for this purpose comprises a copper tubular combined electrical current conductor and conduit for circulating cooling water having a first closed end and a second end connectable to a source of cooling fluid and a source of electricity. At least one, and preferably a plurality, of copper noses extend outwardly from the combined conductor and conduit and both conduct electricity and circulate cooling fluid.

Abstract: A method for producing cylinder linings in an aluminum alloy engine block for an internal combustion engine utilizes plasma spraying of a mixture of powdered molybdenum and powdered steel containing from about 10 to about 70 wt. % molybdenum and from about 90 to about 30 wt. % steel directly to the engine block. The resulting slide layer has good adhesion to the engine block and has high wear resistance.

Abstract: A method for the manufacture of articles such as heat exchangers, heat absorbers, thermal skins, rocket engine components and the like which method comprises providing a substrate or mold, etching or cutting cooling channels therein, filling said channels and processing to form a part which is then fabricated into the final article. In the production method a unique filler or core material comprising a strontium composition is utilized thus rendering a product of high quality and net-shape finish.

Abstract: The invention pertains to a method for the production of an anode for X-ray tubes, and the invention also pertains to the resulting anode. In the invention, a coating that emits X-ray radiation is applied by inductive vacuum plasma spraying onto the base element. Using this method, an improved fatigue crack resistance and a reduced roughening of the coating on the anode is achieved.

Abstract: To provide a substrate consisting of carbon or non-metallic materials containing carbon with a layer of a metal having a high melting point, first an undercoat layer is applied to the substrate by plasma spraying in an inert atmosphere. The undercoat layer predominantly consists of rhenium, molybdenum, zirconium, titan, chrome, niobium, tantalum, hafnium, vanadium, platinum, rhodium or iridium. Onto that undercoat layer, a covering layer can be applied, by plasma spraying as well. In order to reduce the thermo-mechanical stress and to improve the adhesion of the undercoat layer on the surface of the substrate, the substrate is preheated prior to applying the undercoat layer. By means of such a method, carbon-containing substrates can be provided with an undercoat layer and, if required, with a covering layer quickly and reliably at low costs.

Abstract: A method of depositing a bond coat (16) of a thermal barrier coating (TBC) system (14) for a component (10) designed for use in a hostile thermal environment. The method yields a bond coat (16) having an adequate surface roughness for adhering a plasma-sprayed ceramic layer (18), while also exhibiting high density and low oxide content. The method generally entails forming the bond coat (16) by depositing a metal powder on the substrate (12) using a plasma spray or high velocity oxy-fuel (HVOF) technique. The metal powder contains particles that are sufficiently large to incompletely melt during deposition, yielding a surface roughness of at least about 350 microinches Ra. The large particles cause the bond coat (16) to have relatively low density and a propensity to oxidize, both at the surface of the bond coat (16) and internally due to the porosity of the bond coat (16).

Abstract: A flexible film interface includes a flexible film; flexible material attached to a portion of the flexible film; surface metallization on the flexible material, the flexible film having at least one via extending therethrough to the surface metallization; and a floating pad structure including floating pad metallization patterned over the flexible material and the surface metallization, a first portion of the floating pad metallization forming a central pad and a second portion of the floating pad metallization forming at least one extension from the central pad and extending into the at least one via.

Abstract: A method for preparing and coating metal cookware having an interior cooking surface and for the application of a lubricative coating is disclosed. The method includes mechanically spraying the interior cooking surface with an aluminum oxide material to produce a roughened surface and applying by thermal spraying a metallic abrasion resistant layer of substantially pure titanium, titanium oxide and/or titanium nitride. Also disclosed is a cooking utensil having a substrate and an intermediate layer deposited on the substrate by thermally spraying the substrate with a mechanically durable material, said mechanically durable material being selected from the group consisting of chemically pure titanium, titanium-aluminum, nickel-titanium, and titanium 6-4.

Abstract: The present invention generally provides a method for processing a substrate having exposed surfaces of titanium and/or silicon prior to deposition of aluminum. The substrate is positioned adjacent a process zone which provides a nitrogen plasma so that exposed areas of titanium and silicon on the substrate are stuffed with nitrogen to form titanium nitride (TiN) and various compounds of silicon and nitrogen (Si.sub.x N.sub.y), respectively. The nitrogen treated surfaces, i.e, TiN and silicon/nitrogen compounds, are resistant to interaction with aluminum. In this manner, the formation of electrically insulating TiAl.sub.3 and/or the spiking of silicon is reduced or eliminated.

Abstract: A method of preparing electrodes is now described, which electrodes have enhanced adhesion of subsequently applied coatings combined with excellent coating service life. In the method, a substrate metal, such as a valve metal as represented by titanium, is provided with a highly desirable rough surface characteristic for subsequent coating application. This can be achieved by various operations including etching to ensure a roughened surface morphology. In subsequent operations, a barrier layer is provided on the surface of enhanced morphology. This may be achieved by operations including heating, as well as including thermal decomposition of a layer precursor. Subsequent coatings provide enhanced lifetime even in the most rugged commercial environments.