Abstract: The disclosed technology generally relates to coatings, and more particularly to metallic alloy coatings for rotors having nanocrystalline grains. In one aspect, a brake rotor comprises a disc-shaped friction area and a coating having a metallic alloy composition formed on the friction area to form a friction surface configured to contact a brake pad. The metallic alloy composition comprises Fe, Cr, B, C, Mn, Si and Mo as alloying elements that are present at concentrations exceeding impurity concentrations, and wherein the coating comprises nanocrystalline grains having an average grain size less than 100 nm.

Abstract: Embodiments of the systems and methods disclosed herein describe a data verification of electrical electric components and software systems electronically or mechanically coupled to the electric aircraft by a novel process which starts an electric aircraft and receives physical and software information for each aircraft component or system and determines the status of the health of each of those components or systems. An embodiment may further include a monitoring system configured to measure a plurality of data from each aircraft component and a flight controller communicatively coupled to the monitoring system, wherein the data verification can be performed by the flight controller. Further embodiments may include the flight controller generating an output datum from the assessment produced by the data verification and displaying it to a pilot via an output device.

Abstract: A nickel-based superalloy without titanium and a corresponding powder. A process for producing a component, wherein the alloy or the powder is used, in particular for a process for additive manufacture, especially selective laser sintering or selective laser melting. A component having an alloy or produced from the powder or produced by the process.

Abstract: A coating system for a surface of a superalloy component is provided. The coating system includes a MCrAlY coating on the surface of the superalloy component, where M is Ni, Fe, Co, or a combination thereof. The MCrAlY coating generally has a higher chromium content than the superalloy component. The MCrAlY coating also includes a platinum-group metal aluminide diffusion layer. The MCrAlY coating includes Re, Ta, or a mixture thereof. Methods are also provided for forming a coating system on a surface of a superalloy component.

Abstract: For the purpose of simple integration of conductor circuits into composite material components, a method and an apparatus for producing composite material components of this kind are proposed, wherein a conductor circuit is printed onto or applied in some other way to a support, is provided with a thermally activatable adhesive and then the support is applied to a blank of the composite material component for joint curing. The curing at high pressure and high temperature creates a strong connection between the conductor circuit and the composite material component.

Abstract: A blade outer airseal has a body comprising: an inner diameter (ID) surface; an outer diameter (OD) surface; a leading end; and a trailing end. The airseal body has a metallic substrate and a coating system atop the substrate along at least a portion of the inner diameter surface. At least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant; and the metallic matrix comprises, by weight, 35% copper, 30.0-45.0% combined nickel, cobalt, and iron with combined iron and cobalt content at most one-third of the nickel content, 2.0-8.0% aluminum, and 5.0-15.0% chromium.

Abstract: The present invention is directed to repair compositions for thermal barrier coatings and methods of use thereof. The repair compositions include a ceramic composition, a colloidal solution, an aqueous binder, an aqueous dispersant, and an aqueous ammonia solution. The ceramic composition includes a first population of yttria-stabilized zirconia particles having a mean diameter from about 250 nm to about 1000 nm, a second population of yttria-stabilized zirconia particles having a mean diameter from about 2 ?m to about 10 ?m, and a third population of yttria-stabilized zirconia particles having a mean diameter from about 20 ?m to about 250 ?m. One method includes depositing the repair layer onto the damaged region, the repair layer including the repair composition, and heat treating the repair layer.

Abstract: One embodiment provides a composition, comprising: a powder composition comprising alloy that is at least partially amorphous, the alloy comprising chromium, molybdenum, carbon, boron, and iron. One embodiment provides a method of forming a coating, comprising: providing a substrate; and disposing onto the substrate a coating, comprising: powder composition comprising an alloy that is at least partially amorphous, the alloy comprising chromium, molybdenum, carbon, boron, and iron.

Abstract: Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.

Abstract: The invention relates to the use of a particle-containing powdered coating material in a coating method selected from the group consisting of cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying, wherein the particles have a relative deformability factor Vm of at most 0.1 and the relative deformability factor is defined according to Formula (I): V m = d D 50 , ( I ) wherein d is the average smallest thickness of the particles, measured vertical to and in the middle half of the longitudinal axis of the particles, and D50 is the average diameter of the volume-averaged particle-size distribution. The invention furthermore relates to a method for coating.

Abstract: In an example of a method for making a silicon-based active electrode material, a silicon active material precursor is introduced into a carrier gas. Another active material precursor is introduced into the carrier gas prior to, simultaneously with or subsequent to the silicon active material precursor. The other active material precursor is selected from a tin active material precursor, an aluminum active material precursor, a graphene active material precursor, and combinations thereof. The carrier gas containing the precursors is exposed to plasma vaporization, and a material is formed. The material includes i) an alloy of phase separated silicon and tin and/or aluminum, or ii) a graphene layer having silicon nanoparticles and tin nanoparticles, aluminum nanoparticles, or combinations of tin and aluminum nanoparticles deposited on a surface thereof, or iii) a graphene layer having an alloy of phase separated silicon and tin, aluminum, or tin and aluminum deposited on a surface thereof.

Abstract: A method for processing feed material to produce dense and spheroidal products is described. The feed material is comprised of powder particles from the spray-drying technique or solution precursor droplets from ceramic or metallic materials. The feed material is processed using plasma generated from a microwave. The microwave plasma torch employed is capable of generating laminar flow during processing which allows for the production of spheroidal particles with a homogenous materials distribution. This results in products having improved thermal properties, improved corrosion and wear resistance and a higher tolerance to interface stresses.

Abstract: A method for high rate assembly of nanoelements into two-dimensional void patterns on a non-conductive substrate surface utilizes an applied electric field to stabilize against forces resulting from pulling the substrate through the surface of a nanoelement suspension. The electric field contours emanating from a conductive layer in the substrate, covered by an insulating layer, are modified by a patterned photoresist layer, resulting in an increased driving force for nanoelements to migrate from a liquid suspension to voids on a patterned substrate having a non-conductive surface. The method can be used for the production of microscale and nanoscale circuits, sensors, and other electronic devices.

Abstract: A component of a rotary wing aircraft is provided including a surface configured to contact another component of the rotary wing aircraft such that the surface is susceptible to corrosion and/or pitting. The surface has an area from which a portion of material was removed. A structural deposit is formed by cold spraying one or more layers of powdered material within the area. The structural deposit is configured to carry a load applied to the component.

Abstract: A metal wood golf club with a striking face portion made from more than one material is disclosed. More specifically, due to the unique construction of the striking face portion having multiple materials, the present invention utilizes bonding spray deposition process to achieve the desirable bond between the more than one materials used to form the striking face. The striking face portion is formed by creating a chip insert type material utilizing the spray deposition process that is made from a secondary material that is different from the remainder of the striking face portion substantially near a geometric center of the striking face portion; wherein the secondary material has a higher Young's modulus than the remainder of the striking face portion.

Abstract: An alloy composite material comprising an aluminum alloy layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer. An alloy composite material comprising an aluminum alloy layer or base layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer or base layer. The aluminum alloy layer or base layer and the thermal spray alloy layer have a mechanical compatibility to each other of 20-60 MPa as determined using tests specified by ASTM-C633 test. A process of thermal spraying comprising providing a base layer and a feed stock alloy of 20 to 40% Mn and 47 to 76% Fe and thermally spraying the feed stock alloy onto the base layer to form an alloy composite material.

Abstract: A soft magnetic material comprises a plurality of iron-containing particles and an insulating layer on the iron-containing particles, the insulating layer comprising an oxide. The soft magnetic material is an aggregate of permeable micro-domains separated by insulation boundaries.

Abstract: Polycrystalline material comprising a plurality of nano-grains of a crystalline phase of an iron group element and a plurality of crystalline grains of material including carbon (C) or nitrogen (N); each nano-grain having a mean size less than 10 nanometres.

Abstract: Provided is a new catalyst capable of removing carbon monoxide economically without adding particular reaction gas externally. Also provided are a process for producing and an apparatus using such a catalyst. Impregnation of a Ni—Al composite oxide precursor of a nonstoichiometric composition prepared by the solution-spray plasma technique with a ruthenium salt to be supported and performing reduction treatment allows CO methanation reaction to selectively proceed even in the high-temperature range in which CO2 methanation reaction and reverse water-gas-shift reaction proceed preferentially with conventional catalysts. Selective CO methanation reaction occurs reproducibly with another Ni—Al composite oxide precursor or an additive metallic species.

Abstract: A contact element for high voltage direct current switches includes a matrix made of a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold, and alloys thereof. The contact element also includes a foreign phase, which is dispersed in the matrix and is made of a second material selected from the group comprising carbon, tin(II) oxide, tin(IV) oxide, zinc(II) oxide, tungsten, nickel and mixtures thereof. The contact element has a porosity of ?1.0% by volume, based on a total volume of the contact element.

Abstract: A composition, method for depositing the composition on a downhole component, and a downhole tool. The composition includes about 0.25 wt % to about 1.25 wt % of carbon, about 1.0 wt % to about 3.5 wt % of manganese, about 0.1 wt % to about 1.4 wt % of silicon, about 1.0 wt % to about 3.0 wt % of nickel, about 0.0 to about 2.0 wt % of molybdenum, about 0.7 wt % to about 2.5 wt % of aluminum, about 1.0 wt % to about 2.7 wt % of vanadium, about 1.5 wt % to about 3.0 wt % of titanium, about 0.0 wt % to about 6.0 wt % of niobium, about 3.5 wt % to about 5.5 wt % of boron, about 0.0 wt % to about 10.0 wt % tungsten, and a balance of iron.

Abstract: A system for purging a plural component coating application system including: a first pressure regulator for receiving an inert gas, providing the gas at a first pressure; a first valve; a first operator connected to the first valve capable of being controlled by a logic controller; a first check valve; a mixing manifold; a second pressure regulator for receiving an inert gas, providing the gas at a second pressure that is less than the first pressure; a second valve; a second operator connected to the second valve capable of being controlled by a logic controller; a second check valve; a static mixer in fluid communication with the mixing manifold; an outlet from the static mixer for receiving a connection to at least two spraying members; and where the second regulator is capable of providing the second pressure at a pressure that is less than one-fifth of the first pressure.

Abstract: A rotary piston engine comprises a stationary housing and a piston movably accommodated in the housing. The housing and the piston form at least one chamber with a chamber surface. At least one partial portion of the chamber surface has a thermal barrier coat for reducing a thermal conductivity of the partial portion of the chamber surface. At least one partial portion of the chamber surface has a metallic spray coat. A method for producing such a rotary piston engine can also be achieved.

Abstract: Alloy composition for the manufacture of protective coatings, comprising cobalt, nickel, chromium, aluminium, yttrium and iridium in amounts so as to obtain the phases ?, ? and ?, in particular for coating a super-alloy article. Preferably, such super-alloy article is a turbine component.

Abstract: In order to provide a nonmagnetic material for producing parts or coatings adapted for highly wear and corrosion intensive applications, said material comprising preformed particles made of tungsten carbide which are embedded in a metal phase made of a Ni-based alloy. It is suggested that the weight portion of said tungsten carbide particles is in the range between 30 wt. % and 65 wt. % and wherein the Ni-based alloy is a Nickel-Chromium-Molybdenum alloy comprising: (in wt. %): Cr 11.0,-30.0? Mo 5.0-25.0? Fe ?0-10.0 B 0-5.0 Co 0-2.

Abstract: Electrodes for depositing hardfacing alloys containing boron, carbon, chromium, manganese, and silicon on the surface of metal components that are subjected to high thermal and mechanical stresses. The deposited hardfacing alloys have from about 2.5 to about 14.0 atomic weight percent boron and have a hardness on the Rockwell “C” scale of at least about 65 HRC in the first layer of the weld deposit.

Abstract: The inventors have developed a new alloy which is useful in HVOF-spraying of a substrate, such as plungers which are used in glass manufacture. When coated with said alloy, these parts display high wear resistance and consequently longer lifetime.

Abstract: A valve for use in an internal combustion engine is disclosed. The valve includes a stem connected to a fillet disposed between the stem and a seat face. A port receives the stem and accommodates a seat insert that engages the seat face when the valve is in a closed position. The seat insert is fabricated from a non-cobalt-based alloy or an iron-based alloy and the seat face is coated with a cobalt-based alloy or a nickel-based alloy. The coating may be applied using a thermal spray process, such as HVOF.

Abstract: The present invention provides a base metal combination electrode of electronic ceramic component and manufacturing method thereof, wherein said base metal combination electrode comprises a first base metal electrode layer covering on two sides of said electronic ceramic chip and a second base metal electrode layer covering on said first base metal electrode layer, the manufacturing method for base metal combination electrode of electronic ceramic component comprises using thermal spray equipment to spray the electrode material to the surface of electronic ceramic chip. Comparing with using silver paste or copper paste only, it reduces the cost of electrode material without destroying the function of the electrode. The manufacturing method for base metal combination electrode of the present invention has simple technological process, high preparation efficiency and low cost, and it reduces the production cost of electrode of the electronic ceramic component on the whole.

Abstract: The present invention relates to the use of a particle-containing powdered coating material, wherein the surface of the particles is at least partially covered with a coating additive, in cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying. Furthermore, the present invention relates to coating methods, in particular the above-named methods, using the powdered coating material according to the invention.

Abstract: A method for depositing an anticorrosive coating on components, wherein an aluminum-zinc coating is used as an anticorrosive coating, and wherein the anticorrosive coating is deposited by thermal spraying, wherein an inert carrier gas with a reducing gas component is used for the thermal spraying.

Abstract: The invention concerns a nanocrystalline alloy of the formula: Fe3?xAl1+xMyTz wherein: M represents at least one catalytic specie selected from the group consisting of Ru, Ir, Pd, Pt, Rh, Os, Re, Ag and Ni; T represents at least one element selected from the group consisting of Mo, Co, Cr, V, Cu, Zn, Nb, W, Zr, Y, Mn, Cd, Si, B, C, O, N, P, F, S, Cl and Na; x is a number larger than ?1 and smaller than or equal to +1 y is a number larger than 0 and smaller or equal to +1 z is a number ranging between 0 and +1 The invention also concerns the use of this alloy in a nanocrystalline form or not for the fabrication of electrodes which in particular, can be used for the synthesis of sodium chlorate.

Abstract: The present invention relates to a wear-resistant layer, which is preferably used on piston rings for internal combustion engines. The wear-resistant layer comprises: 15-25% by weight iron (Fe), 10-25% by weight tungsten carbide (WC), 30-40% by weight chromium (Cr), 10-25% by weight nickel (Ni), 10-25% by weight molybdenum (Mo), 1-10% by weight carbon (C), 0.1-2% by weight silicon (Si), wherein Cr is present in elemental form and/or as a carbide in the form of Cr2C3. A method for applying the wear resistant layer and a piston ring having such a wear resistant layer are also disclosed.

Abstract: An apparatus and method for thermal spraying a metal coating on a substrate is accomplished with a modified pulsejet and optionally an ejector to assist in preventing oxidation. Metal such as Aluminum or Magnesium may be used. A pulsejet is first initiated by applying fuel, air, and a spark. Metal is inserted continuously in a high volume of metal into a combustion chamber of the pulsejet. The combustion is thereafter controlled resonantly at high frequency and the metal is heated to a molten state. The metal is then transported from the combustion chamber into a tailpipe of said pulsejet and is expelled therefrom at high velocity and deposited on a target substrate.

Abstract: Components of semiconductor material processing chambers are disclosed, which may include a substrate and at least one corrosion-resistant coating formed on a surface thereof. The at least one corrosion-resistant coating is a high purity metal coating formed by a cold-spray technique. An anodized layer can be formed on the high purity metal coating. The anodized layer comprises a process-exposed surface of the component. Semiconductor material processing apparatuses including one or more of the components are also disclosed, the components being selected from the group consisting of a chamber liner, an electrostatic chuck, a focus ring, a chamber wall, an edge ring, a plasma confinement ring, a substrate support, a baffle, a gas distribution plate, a gas distribution ring, a gas nozzle, a heating element, a plasma screen, a transport mechanism, a gas supply system, a lift mechanism, a load lock, a door mechanism, a robotic arm and a fastener.

Abstract: A method of fabricating a composite material includes utilizing a radio frequency plasma process to form a plasma plume comprising nanoparticles. The nanoparticles may comprise boron nitride nanoparticles, silicon carbide nanoparticles, beryllium oxide nanoparticles, or carbon nanoparticles. The nanoparticles may comprise nanotubes or other particles depending on the requirements of a particular application. The nanoparticles are deposited on a substrate by directing a plasma plume towards the substrate. The nanoparticles are formed in the plasma plume immediately prior to being deposited on the substrate. The nanoparticles may form a mechanical bond with the fibers in addition to a chemical bond in the absence of a catalyst. The substrate may comprise a fiber fabric that may optionally be coated with a thin layer of metal. Alternatively, the substrate may comprise a solid material such as a metal sheet or plate.

Abstract: The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance against corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.

Abstract: A method of coating an aluminum alloy or magnesium alloy component, including cleaning and drying surfaces of the component to be coated; suspending a powdered coating material in a carrier gas and feeding the suspended powdered coating material through a plasma torch in a flowing gas; heating the coating material in the plasma torch to a molten or semi-molten state using a nominal power below 25 kW; and depositing the coating material with the plasma torch directly on the surfaces to be coated. The component may be made of a magnesium alloy containing at one or more of zinc, cerium and zirconium, or of an aluminum alloy containing one or more of magnesium, silicon, copper and chromium. The powder material may be made in majority of aluminum.

Abstract: A piston for an internal combustion engine may include a surface in a region on a crankshaft side. The piston may include a thermally conductive coating disposed on the surface via thermal spraying.

Abstract: The invention relates to the use of a particle-containing powdered coating material in a coating method selected from the group consisting of cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying, wherein the particles have a relative deformability factor Vm of at most 0.1 and the relative deformability factor is defined according to Formula (I): V m = d D 50 , ( I ) wherein d is the average smallest thickness of the particles, measured vertical to and in the middle half of the longitudinal axis of the particles, and D50 is the average diameter of the volume-averaged particle-size distribution. The invention furthermore relates to a method for coating.

Abstract: Some embodiments comprise systems, methods, compositions, and apparatus including, but not limited to, thermally sprayed titanium-nitride ceramic particles encapsulated in one of several pure metals or metallic alloys; for producing a high wear-resistant coating on the contacting friction surfaces of machined component parts, including among them, piston rings, piston connecting rods and cylinder liners.

Abstract: A multi-layer protective coating for a substrate arranged in or on a vessel and method of forming multi-layer protective coating on a substrate arranged in or on a vessel. Multi-layer protective coating includes a thermal sprayed bonding layer formed on and in contact with a first face of the substrate prepared in a manner to allow the bonding layer to adhere, the bonding layer having a substrate face and a non-substrate face, a resistance layer made of a material resistant to impact forces and corrosion caused by a corrosive environment in a vicinity of the substrate arranged in or on the vessel, the resistance layer formed on and in contact with the non-substrate face of the bonding layer, the resistance layer having a bond face and a non-bond face, and a sealant layer formed on and in contact with the non-bond face of the resistance layer.

Abstract: A plasma gun system comprising: a plasma gun comprising an outlet, wherein the plasma gun is configured to generate a plasma stream and provide the plasma stream to the outlet; and a plasma gun extension assembly configured to be coupled to the plasma gun, wherein the plasma gun extension assembly comprises an extension chamber and a port, the extension chamber having an interior diameter defined by a chamber wall and being configured to receive the plasma stream from the outlet of the plasma gun and to enable the plasma stream to expand upon entering the extension chamber, and the port being configured to introduce a powder to the expanded plasma stream at a location outside of the plasma gun.

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 system for coating a surface comprises providing a source of amorphous metal, providing ceramic particles, and applying the amorphous metal and the ceramic particles to the surface by a spray. The coating comprises a composite material made of amorphous metal that contains one or more of the following elements in the specified range of composition: yttrium (?1 atomic %), chromium (14 to 18 atomic %), molybdenum (?7 atomic %), tungsten (?1 atomic %), boron (?5 atomic %), or carbon (?4 atomic %).

Abstract: A system for coating a surface comprising providing a source of amorphous metal that contains more than 11 elements and applying the amorphous metal that contains more than 11 elements to the surface by a spray. Also a coating comprising a composite material made of amorphous metal that contains more than 11 elements. An apparatus for producing a corrosion-resistant amorphous-metal coating on a structure comprises a deposition chamber, a deposition source in the deposition chamber that produces a deposition spray, the deposition source containing a composite material made of amorphous metal that contains more than 11 elements, and a system that directs the deposition spray onto the structure.

Abstract: A class of nickel based alloys having a fine grain structure resistant to stress corrosion cracking, and methods of alloy design to produce further alloys within the class are presented. The alloys act as suitable welding materials in similar applications to that of Alloy 622. The fine-grained structure of these novel alloys may also be advantageous for other reasons as well such as wear, impact, abrasion, corrosion, etc. These alloys have similar phases to Alloy 622 in that they are composed primarily of austenitic nickel, however the phase morphology is a much finer grained structure opposed to the long dendritic grains common to Alloy 622 when it is subject to cooling rates from a liquid state inherent to the welding process.

Abstract: Coatings on a substrate and application methods result in coatings that can withstand different types or groups of bulk cargo and operations. This novel approach includes use of a combination of layers of coating materials at certain thicknesses and applied with certain techniques. In certain embodiments, the coating system includes coatings applied to a pretreated substrate, e.g., blasted steel cargo hold plates of an oceangoing vessel. The coatings include a bond layer and a resistance layer, e.g., an anti-corrosive layer tailored to resist at least one of corrosion, erosion, impact and wear of the substrate.

Abstract: Processes, systems, and apparatuses are disclosed for forming products from atomized metals and alloys. A stream of molten alloy and/or a series of droplets of molten alloy are produced. The molten alloy is atomized to produce electrically-charged particles of the molten alloy by impinging electrons on the stream of molten alloy and/or the series of droplets of molten alloy. The electrically-charged molten alloy particles are accelerated with at least one of an electrostatic field and an electromagnetic field. The accelerating molten alloy particles are cooled to a temperature that is less than a solidus temperature of the molten alloy particles so that the molten alloy particles solidify while accelerating. The solid alloy particles are impacted onto a substrate and the impacting particles deform and metallurgically bond to the substrate to produce a solid alloy preform.

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.