Abstract: A method for coating metal cookware includes the steps of (1) cleaning a cooking surface of the metal cookware; (2) roughening the cooking surface by blasting aluminum oxide particles against the cleaned cooking surface; (3) forming a scratch-resistant layer on the roughened cooking surface by electric-arc spraying an aluminum alloy onto the roughened cooking surface, the scratch-resistant layer covering about 50-90% of the area of the roughened cooking surface; (4) forming an oxide film on the scratch-resistant layer and the roughened cooking surface by anodic oxidation; and (5) applying an anti-stick film of fluorocarbon resin on the oxide film.

Abstract: A method of fluxing a cast light-weight metal substrate for thermally adhering sprayed metallic coatings thereto, comprising: (a) preparing the substrate to be clean of grease and oil and to have a uniform and homogeneous surface energy; (b) electrostatically depositing a dry flux powder coating onto such prepared surface; and (c) thermally depositing melted metal onto and across the flux coated surface to further thermally activate the flux if not already activated, for stripping away any substrate oxides and to thermally metallurgically bond the deposited molten metal to the substrate.

Abstract: The method of preparing an adhesive layer on a substrate includes introducing a thermally reactive powder comprising aluminum and a second metal into a plasma torch, wherein the thermally reactive powder is substantially free of binder, additive and contaminant and does not contain a significant amount of intermetallic compound into a plasma torch. An exothermic reaction is initiated within the thermally reactive powders in the plasma torch and the exotherming powders impinge onto a substrate, such that the heat generated by the exothermic reaction is generated predominantly on the substrate.

Abstract: A method of thermally spraying at least one adherent metallic coating onto an unroughened cleansed aluminum or aluminum alloy substrate to produce a coated substrate, comprising: wire-arc thermally spraying of melted metallic bonding droplets and fluxing particles onto the substrate using air propulsion to concurrently adherently deposit flux particles and bonding droplets, the spraying using air propulsion and a wire feedstock having a core and a sheath, the wire core being constituted of both metal powder readily metallurgically bondable to the substrate and a fluxing powder that readily deoxidizes the substrate, the wire sheath being constituted of pliable metal that is metallurgically compatible with the core metal powder, the fluxing powder having a halide salt chemistry effective to deoxidize the substrate upon contact of the melted fluxing powder therewith, said fluxing powder and bonding metal having a particle size that more uniformly promotes distribution throughout said spray.

Abstract: A method of depositing a bond coat (16) of a thermal barrier coating (TBC) system (14) for components designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components (10) of a gas turbine engine. The method yields a bond coat (16) having an adequate surface roughness for adhering a plasma-sprayed ceramic layer (18) while also producing a bond coat (16) that is dense with low porosity, thereby yielding a thermal barrier coating system (14) that is highly resistant to spallation. The method generally entails forming the bond coat (16) by depositing two metal powders on the substrate (12) using either a vacuum plasma spraying (VPS) or high velocity oxy-fuel (HVOF) technique. The particle size distributions of the two powders are chosen to yield a bimodal (dual-peak) particle size distribution that will produce a VPS and HVOF bond coat (16) characterized by a macro-surface roughness of at least about 350 microinches Ra attributable to particles of the coarser powder.

Abstract: A thermal barrier coating system and a method for forming the coating system on an article designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The method is particularly directed to a coating system comprising an APS bond coat on which a thermal-insulating APS ceramic layer is deposited, wherein the oxidation resistance of the bond coat and the spallation resistance of the ceramic layer are increased by diffusing platinum, palladium, hafnium, rhenium and/or rhodium into the bond coat. The diffusion process is performed so as not to alter the surface roughness of the bond coat, which is maintained in a range of about 200 to about 500 .mu.inch Ra.

Abstract: A gas turbine abradable seal is prepared by plasma spraying an oxidation resistant metallic material and boron nitride. The resultant structure comprises a metallic matrix encompassing a lubricating amount of boron nitride, with porosity of less than about 15 percent and a fabricated surface roughness of less than about 600 microinches. The reduced surface roughness and substantially reduced permeability of this seal provide substantially enhanced engine efficiency, and improved durability.

Abstract: A dental care material comprising a titanium sintered body has no harmful effects on the human body and easily produces products with complicated shapes having a high level of strength. A mixture of titanium powder and an organic binder is injection molded and subjected to binder removal and sintering processes to form a bracket for orthodontic or dental implant materials. Pure titanium powder, with an average granule diameter of no more than 40 .mu.m, a carbon content by weight of no more than 0.3%, and an oxygen content by weight of no more than 0.6%, preferably is used to produce a titanium sintered body of combined carbon and oxygen content by weight of no more than 1.0%. Colored layers can be formed on the surface of the titanium sintered body using various methods as needed.

Abstract: A durable coating process which provides improved adhesive bond strength between the coating and its substrate. This process utilizes spray parameters which generate a unique plasma coating that can be applied through a liquid environment between the spray gun nozzle and the substrate to provide combined ion cleaning, etching and activation of the surface to be coated. The improved surface conditioning allows the creation of an exceptionally strong metallurgical bond at the interface between the splattered droplets of the coating material and the substrate. The improved plasma coating process utilizes a relatively short nozzle-to-work surface distance and is therefore suitable for use directly in a liquid such as water in order to keep the substrate from overheating, which may be more likely to occur if the coating were applied in a gas or vacuum environment.

Abstract: Method of depositing a metal base coating containing a self-lubricating oxide phase and one or more wear resistant phases, by: preparing at least one light metal substrate surface to be essentially oxide-free and in a condition to adherently receive the coating, plasma spraying a supply of metal (M) powder particles onto the substrate surface to produce a composite coating of such metal (M) and an oxide (MO.sub.

Abstract: A method of eliminating scrubbing noise between metal to metal (or metal to ceramic) contact members that experience articulating swiveling interengagement at high force levels in excess of 5,000 psi. The method comprises: (a) preparing the interface to present at least one fresh mechanically adherable stiff surface; (b) thermally spraying a top coating thereonto consisting of at least one of (i) a self-lubricating metal, ceramic material or metal alloy, and (ii) a compliant metal; and (c) placing the coating interface into service to subject it to repeating articulating swiveling contact that functions to microweld the coating to the surface under normal operating conditions.

Abstract: A method for coating metal cookware having a cooking surface includes the steps of: (1) roughening and cleaning the cooking surface of the metal cookware; (2) applying a metallic scratch-resistant layer onto the roughened and cleaned cooking surface by electric-arc spraying; and (3) applying an anti-stick layer onto the scratch-resistant layer. The step (2) includes electric-arc spraying a stainless steel and an aluminum alloy onto the cooking surface of the metal cookware in order to improve corrosion resistance of the scratch-resistant layer. The stainless steel consists of less than 0.2% by weight of carbon, 17-20% by weight of chromium, 7-10% by weight of nickel and the remainder being iron. The aluminum alloy consists of 0.25% by weight of silicon, 0.4% by weight of iron, 0.10% by weight of copper, 0.05-0.20% by weight of manganese, 4.5-5.5% by weight of magnesium, 0.05-0.20% by weight of chromium, 0.10% by weight of zinc, 0.06-0.20% by weight of titanium, 0.

Abstract: A thermal spray process for producing a MCrAlY-based coating wherein M is selected from the group consisting of iron, cobalt, nickel and mixtures thereof and wherein the oxygen in the fuel-oxidant mixture of the thermal spray process converts a substantial portion of the yttrium component to Y.sub.2 O.sub.3, a minor portion of the aluminum component to Al.sub.2 O.sub.3, and the Y.sub.2 O.sub.3 and Al.sub.2 O.sub.3 are present in an amount of less than 15 volume percent of the coating.

Abstract: A process for reducing oxygen content in thermally sprayed metal coatings comprises the following steps. A metal powder is provided. The metal powder has a particle size in the range of from about 10 .mu.m to about 500 .mu.m. Carbon is adhered and coated to the metal powder to form a carbon coated metal powder. The carbon is present in the range of from about 0.1% to about 2.0% by weight of the carbon coated metal powder. The carbon coated metal powder is thermally sprayed onto a substrate and a metal coating is deposited on the substrate. The metal coating has a lower oxygen content compared to the oxygen content of the carbon coated metal powder.

Abstract: The invention is to a method for producing a high surface substrate. A mask is positioned (31) over a substrate to define a deposition area. Thereafter at least two dissimilar materials are simultaneously deposited (32) through the mask onto the deposition area. Then one of the deposited materials is selectively removed (33) to provide a high surface area deposited substrate.

Abstract: A method of bonding a thermally sprayed coating to a non-roughened light metal (i.e. cast aluminum-based) surface. The method comprises the steps of (a) depositing a flux material (i.e. potassium aluminum's fluoride containing up to 50 molar % other fluoride salts) onto such cast surface which has been cleansed to be substantially free of grease and oils, such deposition providing a dry flux coated surface, the flux being capable of removing oxide on the cast surface and having a melting temperature below that of the cast surface; (b) thermally activating the flux in the flux coated surface to melt and dissolve any oxide residing on the cast surface; and (c) concurrently therewith or subsequent to step (b) thermally spraying metallic droplets or particles onto the flux coated surface to form a metallic coating that is metallurgically bonded to the cast surface.

Abstract: A method for applying a coating of catalytic material onto a metallic substrate involves thermal spray deposition of refractory oxide particles directly onto the substrate, preferably to attain an undercoat having a surface roughness of Ra 3 or greater. The catalytic material may then be applied to the undercoated substrate in any convenient manner. In a particular embodiment, the metallic substrate is treated by grit blasting prior to the application of an undercoat principally containing alumina. The coated substrate can be used in the assembly of a catalyst member for the treatment of exhaust gases.

Abstract: This invention discloses methods of making new and improved multi-layer coatings for gas turbine engine parts that are exposed to elevated temperatures, such as blades and vanes in the high pressure compressor and turbine of multi-stage aircraft engines, by applying a diamond film over columnar thermal barrier coatings such as yttria-stabilized zirconia, improving the erosion resistance of the thermal barrier coating.

Abstract: A method for reducing oxygen content in metal coatings deposited by gas stabilized plasma spray techniques comprises the following steps. A metal powder is provided. Carbon is adhered and coated to the metal powder and a carbon coated metal powder is formed. A primary gas is provided to a plasma spray gun at a flow rate in the range of about 30-80 liter/min. A carrier gas is also provided to the plasma spray gun at a flow rate in the range of about 4-8 liter/min. The carbon coated metal powder is provided to the plasma gun at a flow rate in the range of about 30-85 gms/min. The plasma spray gun is positioned at a stand-off distance in the range of about 100-175 mm from a substrate. The plasma spray gun is energized with power in the range of about 28-42 kW. The carbon coated metal powder is sprayed onto the substrate and a metal coating having an oxygen content at least 20% by weight less than an oxygen content of the metal powder, is deposited.

Abstract: A composite coating (1) resistant to wear is applied onto a substrate (2) and contains a mixture of hard material particles (3) and particles (5) of a solid lubricant (6). The particles (3, 5) are incorporated in a binder alloy (4). The lubricant particles are each enclosed by a protective envelope (7). The protective envelope substantially prevents bonding between components of the lubricant (6) on the one hand and components of the binder alloy (4) as well as of the hard material particles (3) on the other hand.

Abstract: A metal detector and distance sensor for a motor vehicle. A departure of the motor vehicle from a correct path indicated by one or two metal lines covered with paint in the road is signaled. The metals lines are formed by projecting a jet of metal in the gaseous state at high speed onto the road surface. A covering of paint is then formed over the metal line on the road surface. A turbine supplied by an air compressor projects the jet of metal in the gaseous state from a vehicle or a trailer having a metal supply device and a painting device thereon. A display indicates the direction of departure from the correct path and the distance separating the motor vehicle from a preceding vehicle. Alarm signals can be emitted upon the departure.

Abstract: A hard-facing material source is an article whose net composition is, in weight percent, from about 20 to about 35 percent chromium, from about 2 to about 5 percent boron, from about 1 to about 2.5 percent silicon, from 0 to about 0.5 percent carbon, from about 0.5 to about 2 percent manganese, and from about 0.2 to about 1.0 percent titanium, balance iron and incidental impurities. The article may be a powder or a hollow tube with a powder packed therein. The hard-facing material source is thermally applied to a substrate by spraying or welding.

Abstract: A method of treating a light metal cylinder bore wall to adherently receive a thermally sprayed metallic coating, that comprises (a) honing the wall to produce a net cylinder shape surface by use of spiral overlapping cross-abrasions having certain peaks and valleys of the abrasions folded over and molded to create tears, folds and undercuts rendering a hook and ladder effect, the honing being carried out with the use of a machining coolant to prevent burnishing of the walls; (b) either concurrently or shortly after step (a), washing the honed surface with a hot alkaline solution comprising (i) a non-soaping aluminate forming agent (sodium xanthate) that produces a residue on the walls, and (ii) surfactants that facilitate wetting of the walls even when some steam bubbles may be present; (c) rinsing the washed surfaces without disturbing the residue; and (d) thermally spraying a metallic bond coat and top coat on the honed and washed surface to render adhesion between the coating and prepared surface that is

Abstract: A process and apparatus for the preparation and coating of the surface of a substrate by thermal projection, in which the surface of the substrate is progressively subjected to laser irradiation thereby at least partially to eliminate a superficial contaminating film on the surface of the substrate, and then there is projected by a thermal projection device a deposit material on the surface thus prepared immediately after the preparation. The surface of the substrate is subjected to successive laser and thermal projection treatments thereby to lay down on the surface a plurality of layers of deposit material. The substrate can be cylindrical, and can be rotated about its axis while continuously applying laser radiation and thermal projection thereto, with the substrate rotating in a direction such that the surface of the substrate is subjected first to laser radiation and subsequently to thermal projection. The laser is a pulsed laser.

Abstract: The present invention comprises a method for preparing a surface for application of a non-stick coating, the method wherein the surface to be prepared for non-stick coating is prepared by thermally spraying a stainless steel alloy containing at most 6.0% aluminum, and is substantially free of Nickel. The present invention further includes a cooking utensil having a substrate to which an intermediate layer, for receiving the non-stick coating, is prepared by thermally spraying the stainless steel alloy containing at most 6.0% aluminum, and is substantially free of Nickel.

Abstract: The present invention relates to alloys in which the essential constituent is aluminum, metal deposits produced from these alloys, substrates coated with these alloys and the applications of these alloys. The alloys of the present invention are characterized in thatthey have the following atomic composition (I):Al.sub.a Cu.sub.b Co.sub.b' (B,C).sub.c M.sub.d N.sub.e I.sub.f(I)a+b+b'+c+d+e+f=100, expressed as number of atoms, a.gtoreq.50, 0.ltoreq.b<14, 0.ltoreq.b'.ltoreq.22, 0<b+b'.ltoreq.30, 0.ltoreq.c.ltoreq.5, 8.ltoreq.d.ltoreq.30, 0.ltoreq.e.ltoreq.4, f.ltoreq.2, where M represents one or more elements chosen from Fe, Cr, Mn, Ni, Ru, Os, Mo, V, Mg, Zn and Pd; N represents one or more elements chosen from W, Ti, Zr, Hf, Rh, Nb, Ta, Y, Si, Ge and the rare earths; I represents the inevitable production impurities;and they contain at least 30% by mass of one or more quasicrystalline phases.

Abstract: A method of preparing the surface of a conductive metal to be non-smooth and non-passivated for reception of thermal sprayed coatings. The method comprises melting and rapidly solidifying globules of the surface by electrical discharge by bring an electrode (anode) in close gap-sparking proximity to the surface, filling the gap with an electrolyte containing a halogenated hydrocarbon fluid present in an amount of 2-5% of the electrolyte, and imposing a pulsed DC voltage (i.e. 20-100 volts at 40-200 amps) on the electrode to provide cyclical sparking between the electrode and the surface through the electrolyte resulting in a breakdown of the hydrocarbon to release nascent halogen atoms which attack the surface to prevent passivation during melting and solidification of the globules. The electrolyte is preferably cooled to a temperature below 65.degree. F.

Abstract: An element for thermally protecting a substrate is deposited on the substrate and comprises a quasicrystalline aluminium alloy having a thermal diffusivity lower than 2.5.times.10.sup.-6 m.sup.2 /s at room temperature and a thermal diffusivity, within the temperature range 650.degree.-750.degree. C., which does not exceed its thermal diffusivity at room temperature by a factor greater than 3. The element may be used to provide heat barriers or bonding layers for substrates. The heat protection element, used in the form of a heat barrier or in the form of a bond coat for heat barriers, exhibits good thermal insulation properties, good mechanical properties, a low specific mass, good resistance to corrosion, and great ease of processing. Further, the invention is useful in limiting heat transfer towards or from parts and components of fittings in many household and industrial devices, for example, heating or cooking devices, smoothing irons, automobile components, and in aeronautic components.

Abstract: The present invention relates to a process for producing a metallic catalyst layer or coating which serves for effectuating the removal of hydrogen from a gas mixture containing hydrogen and oxygen. The catalyst layer itself which is porous, comprises a metal, such as palladium (Pd) or platinum (Pt), or alloys of these metals, which catalytically influence the oxidation of hydrogen. The metal or the metal alloy is applied as a catalyst layer or coating onto a carrier material or substrate by either plasma spraying or flame spraying together with a jet of an inert gas. The present invention also provides a catalyst through the intermediary of a catalyst layer which is produced in accordance with the process of the instant invention.

Abstract: Erosion and wear resistant iron alloy, comprising: Cr 20.0-36.0% by weight, B 2.5-5.0% by weight, Mn 0.5-3.2% by weight, Si 0.05-0.6 by weight, Mo 0.3-2.5% by weight, V 0.05-0.3% by weight, Nb 0.03-0.3% by weight, P 0.5% by weight or less, C 0.05-0.3% by weight, and a trace of unavoidable impurities, which confers superior corrosion and wear resistance upon abraded or corroded portions by coating or molding.

Abstract: A method or forming binderless clad powders using a high energy ball mill, preferably an attritor-type ball mill, is described. The binderless clad powders are formed by combining and processing a core material powder and a coating material (either a powder with significantly smaller particle size than the core material powder or a brittle material that will quickly form a powder with significantly smaller particle size than the core material powder) in a high energy ball mill for a relatively short time (generally less than one hour). The processing time employed is such that the particle size of the core material powder is not significantly reduced but that the clad powders are formed. At least one of the two materials (i.e., core forming material or coating forming material) must be deformable within the high energy ball mill. Such binderless clad powders are suitable for use as thermal spray powders and which can be thermally sprayed to form coatings on a various substrates.

Abstract: A method of preparing and coating cylindrical bore surfaces of an aluminum workpiece that comprises (a) inserting and rotationally reciprocally moving a plurality of honing elements against the bore surface with a pressure of at least 30 psi to effect a pattern of spiral overlapping abrasions on said surface, each element being constituted of multifaceted, irregular-shaped, abrasive particles (i.e., diamond or SiC) having a particle size of 30-1300 micrometers. The particles, when in contact with the surface, plow micro-sized, non-smooth and irregularly spaced grooves in the aluminum workpiece resulting in spiral peaks and valleys along the direction of movement of the particles, whereupon repeated reciprocation and rotation of the elements (i.e.

Abstract: A method and apparatus for coating piston rings by producing droplets of molybdenum and stainless steel from these materials in wire form which are sprayed, preferably in equal amounts to coat the outer surfaces of the rings. A plurality of rings are mounted on a body which are moved in a helical path during the spraying. A nozzle is used having a central passage through which the wire is fed and two sets of passages, one set for an oxy-acetylene mixture and the other for compressed air, with the outlet orifices of the two sets of passages arranged in concentric rings around the central passage outlet orifice.

Abstract: Method of depositing an Fe.sub.x O comprising coating onto a light metal substrate by use of wire-arc thermal spraying that propels atomized droplets by use of atomizing gases, comprising: preparing at least one surface of the light metal substrate to present an exposed essentially non-oxidized substrate surface; and thermally spraying melted droplets of a steel feedstock wire onto the prepared surface by use of propellant gases to deposit a composite coating, the gases being controlled as to content to regulate the exposure of the droplets to oxygen so that Fe.sub.x O is substantially the only iron oxide formed during spraying, x being 0.5-1.5.

Abstract: A method for forming a hardened coating on a workpiece, such as a corrugating roll, having an undulated surface. A high velocity oxygen fueled gun is aligned with the undulated surface and a coating material is sprayed onto the surface from the gun to form a hardened coating having substantially uniform surface characteristics. The coating material is a tungsten carbide-cobalt material, or other hard carbide or oxide materials, which is sprayed onto the surface in a direction which is parallel to and offset from a plane passing through the longitudinal center of the roll. During the spraying operation, the gun is traversed along the length of the roll while the roll is rotated.

Abstract: A protective coating resistant to corrosion at medium and high temperatures is applied on a nickel-based or cobalt-based superalloy component. The protective coating essentially consists of the following elements (in percent by weight): 25 to 40% nickel, 28 to 32% chromium, 7 to 9% aluminum, 1 to 2% silicon, 0.3 to 1% of at least one reactive element of the rare earths, at least 5% cobalt; and impurities, as well as selectively from 0 to 15% of at least one of the elements of the group consisting of rhenium, platinum, palladium, zirconium, manganese, tungsten, titanium, molybdenum, niobium, iron, hafnium, and tantalum. The total share of the elements of the group is from 0 to a maximum of 15% and a remainder of at least 5% cobalt. The component and the coating applied thereon have a ductile brittle transition temperature below 500.degree. C.

Abstract: An element for thermally protecting a substrate is deposited on the substrate and comprises a quasicrystalline aluminum alloy having a thermal diffusivity lower than 2.5.times.10.sup.-6 m.sup.2 /s at room temperature and a thermal diffusivity, within the temperature range 650.degree.-750.degree. C., which does not exceed its thermal diffusivity at room temperature by a factor greater than 3. The element may be used to provide heat barriers or bonding layers for substrates. The heat protection element, used in the form of a heat barrier or in the form of a bond coat for neat barriers, exhibits good thermal insulation properties, good mechanical properties, a low specific mass, good resistance to corrosion, and great ease of processing. Further, the invention is useful in limiting heat transfer towards or from parts and components of fittings in many household and industrial devices, for example, heating or cooking devices, smoothing irons, automobile components, and in aeronautic components.

Abstract: A layer of material is thermally sprayed onto a portion of the surface of a vehicle wheel rim drop well with an arc plasma spray gun. Before spraying, the drop well surface is prepared by removing any dirt, oil and oxides. The sprayed layer has a greater density than the metal forming the wheel rim and reduces the porosity of the drop well.

Abstract: The present invention resides in a white thermal control surface resistant to darkening due to exposure to X-rays and ultraviolet radiation. The surface comprises a substrate and a ceramic zirconium orthosilicate coating on said substrate. The zirconium orthosilicate coating is obtained by plasma-spray applying particles of zirconium orthosilicate onto the substrate. The particles of zirconium orthosilicate are doped with an oxide of a +3 valent metal. The metal ions of said +3 valent metal oxide are dispersed substantially uniformly throughout said particles.

Abstract: System and method for controlling alloy composition during molecular beam epitaxy growth of group III-V ternaries at high substrate temperature or under any conditions which give rise to significant desorption rates is described which incorporates desorption mass spectrometry in a real time feedback loop for continuous monitoring and control of layer composition by control of incident group V (e.g., arsenic) flux.

Abstract: The present invention relates to a process for producing a metallic catalyst layer or coating which serves for effectuating the removal of hydrogen from a gas mixture containing hydrogen and oxygen. The catalyst layer itself which is porous, comprises a metal, such as palladium (Pd) or platinum (Pt), or alloys of these metals, which catalytically influence the oxidation of hydrogen. The metal or the metal alloy is applied as a catalyst layer or coating onto a carrier material or substrate by either plasma spraying or flame spraying. The present invention also provides a catalyst through the intermediary of a catalyst layer which is produced in accordance with the process of the instant invention.

Abstract: Protection of a metal surface is carried out by applying a coating of vitreous enamel to the surface so that the enamel forms a strong bond with the metal and then spraying a coating of an atomized protective metal on the enamel. Preferably a peening operation is carried out on the surface of the sprayed metal simultaneously with or immediately after the spraying of the metal. The method is particularly advantageous in protecting steel marine structures against corrosion and, where the protective metal is cupro-nickel, fouling by marine creatures. The vitreous enamel forms an electrically insulating layer preventing galvanic action between the steel and the cupro-nickel in the presence of sea water.

Abstract: A method is described for producing a catalyst layer consisting of a metal alloy with palladium or platinum as the primary meal and at least one other meal which has a melting point lower than that of the primary meal and which forms with the primary metal homogeneous mixed crystals that are rich in the primary metal. In the method, a powder of the at least one other metal is applied first to a carrier body followed by application of a powder of the primary metal. The powders are successively applied to the carrier body in this order, with at least the powder of the primary metal being sprayed on by thermal means.

Abstract: A coated layer of this invention is composed of a lower alloy-coated layer 2 formed of an MCrAlY alloy whose principal element is Co or Co and Ni, an upper alloy-coated layer 1 formed of an MCrAlY alloy whose principal element is Ni and a portion 4 in which an Al content of the surface portion of the upper coated layer 1 is largest and is reduced gradually towards a more internal part. Manufacturing thereof involves the steps of forming the lower and upper coated layers and effecting an Al diffusion treatment into the upper coated layer. The upper coated layer having the portion which exhibits the large Al content contributes to a high-temperature anticorrosive property. A gas turbine blade is provided with the alloy-coated layer, wherein the lower coated layer incorporates a composite function to prevent a high-temperature corrosion of a base material when cracks are caused in the upper coated layer due to thermal stress.

Abstract: A method for forming a biocompatible component from a biocompatible thermoplastic material and a biocompatible fibrous material using an isostatic press. The method includes the steps of placing the biocompatible thermoplastic material and the biocompatible fibrous material in a flexible container. The flexible container is then heated under pressure so as to cause the biocompatible thermoplastic material to encapsulate the biocompatible fibrous material. The flexible container is then cooled so as to form the biocompatible component.

Abstract: A particle of an inorganic or metallic material which is coated on the surface with ultrafines of an inorganic or metallic material. The coated particle is produced by introducing the particles of the inorganic or metallic material to be coated into a stream carrying the ultrafines of the inorganic or metallic material formed in a vapor phase and bringing the particles to be coated into contact with said ultrafines in a fluidized state. The coated particles are used for the production of a sintered product.

Abstract: A heat transfer element (2) for use in boiling a liquid is produced by spraying a substrate, such as a heat exchanger tube, with a plasma of liquified metal particles and concurrently spraying the substrate with liquid carbon dioxide to provide a cooling effect. Preferably the metal particle spray (4) and the carbon dioxide spray (8) are spaced apart, and there is relative movement between the sprays and the substrate, such that a given area of the substrate is precooled by the cold carbon dioxide just prior to liquified metal particles impinging thereon. A shroud (6) may assist in directing the liquid carbon dioxide first onto the substrate, then into the spray of liquified metal particles.

Abstract: A method and apparatus for increasing blade fatigue strength in a turbine engine. The blades in the turbine engine are configured so as to reduce stress at the tip of the blades during operation of the turbine engine, thus increasing blade fatigue strength. This stress reduction helps to counteract the detrimental effect of abrasive tip coatings on blade fatigue strength. In one embodiment, the tip of the blade is chamfered in order to reduce the stress on the tip of the blade. An abrasive coating is then applied to the tip of the blade to assist the blade in seating into an abradable outer air seal. In another embodiment, an abrasive coating is applied to a center portion of the tip of the blade, with the periphery of the abrasive coating being set back from the opposing surfaces of the blade.

Abstract: A method of manufacturing composite magnetic component comprising: a magnetic member or a magnetic base member made of a magnetic material; and a non-magnetic region as a modified magnetic property section being provided in a portion of said magnetic member or magnetic base member in the entire thickness thereof and having a magnetic property modified though composition modified by means of irradiation of an energy beam.

Abstract: A journal bearing assembly includes a steel bearing body and a Babbitt metal liner which defines an internal bearing surface and provides a sliding bearing for a rotating journal. A porous metal bonding layer of NiAl 80/20 or AlSi 12 is applied between the bearing body and the liner. The bonding layer is spray deposited onto the bearing body and the liner is spray deposited onto the bonding layer. The liner is most porous at the bonding layer interface with decreasing porosity toward the bearing surface. The bonding layer may be flame sprayed or applied in powder form and fused. Similarly, the liner may be flame sprayed or applied in powder form and fused.