Abstract: A method for preparing a scratch and abrasion resistant surface on unroughened aluminum or stainless steel cookware, for subsequent coating with a nonstick polymer resin, such as a fluoropolymer, in a liquid and/or powder medium. The scratch and abrasion resistant surface consists of a thermally sprayed aluminum or stainless steel, respectively. A metal coated substrate produced by this method and an article subsequently coated with a fluoropolymer surface by this method are also described.

Abstract: A ceramic coating method for coating a ceramic on a metallic substrate is disclosed where a ceramic material is coated on a surface of a metallic substrate by continuously changing the composition of a mixture of a ceramic material and a metal to form a ceramic coating film on a surface of the metallic substrate. A heat treatment then is effected to the ceramic coated metallic substrate so as to induce a residual stress due to compression on a surface of the ceramic coating film, thereby improving the durability of the ceramic coating film.

Abstract: In a method of coating easily oxidisable materials by plasma powder build-up welding of additive materials in powder form using alternating current or direct current with superimposed alternating current to produce a plasma transferred arc for powder build-up welding in accordance with patent application No 196 26 941.5 a CuNi-alloy is used as an additive welding material with additions (in % by weight) of:______________________________________ Fe below about 10; Cr below about 5; B below about 4; Si below about 4; C with about 1.5; ______________________________________with a degree of mixing of more than 40% by volume.

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 improved thermal barrier coating and method for producing and applying such is disclosed herein. The thermal barrier coating includes a high temperature substrate, a first bond coat layer applied to the substrate of MCrAlX, and a second bond coat layer of MCrAlX with particles of a particulate dispersed throughout the MCrAlX and the preferred particulate is Al.sub.2 O.sub.3. The particles of the particulate dispersed throughout the second bond coat layer preferably have a diameter of less then the height of the peaks of the second bond coat layer, or a diameter of less than 5 .mu.m. The method of producing the second bond coat layer may either include the steps of mechanical alloying of particles throughout the second bond coat layer, attrition milling the particles of the particulate throughout the second bond coat layer, or using electrophoresis to disperse the particles throughout the second bond coat layer.

Abstract: The present invention is directed to a coating process for forming a high ality, high ductility, metallurgically bonded coating on a substrate or part. The process comprises applying a coating to the substrate using an HVOF spray coating technique and subjecting the coated substrate to a stepped heat treatment for diffusing the coating into the substrate while substantially avoiding the formation of macro cracks.

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 coating for a cylinder bore of a reciprocating engine with an iron, aluminum, or magnesium base comprises a hypereutectic aluminum/silicon alloy. The alloy is applied to a cylinder wall by thermal spraying.

Abstract: Heat treated, spray formed articles are disclosed which exhibit crack growth rates and resistance to stress rupture comparable to corresponding, forged articles. The articles are first formed by depositing molten metal droplets, e.g., of IN 718, on a substrate to form a rough article. The articles are HIP'ed and then processed by heat treating, which includes solution, stabilization and precipitation heat treatments. The resultant articles have fine average grain sizes compared to forged and conventionally heat treated material, as well as yield and tensile strengths comparable to forged material. Importantly, the articles also exhibit low crack growth rates and stress rupture resistance, e.g., comparable to forged material, and have an isotropic microstructure. The articles can be used in place of forged articles.

Abstract: A method for applying a functionally gradient coating on a component, having a surface and subjected to one or more of rolling, sliding, abrasion and bending contacts, including the step of thermally spraying a functionally gradient material (FGM) on said surface that forms an FGM coating, said FGM coating having a thickness, a plurality of material compositions and a plurality of elastic modulus profiles. Each elastic modulus profile consists of a plurality of elastic modulii at a plurality of corresponding points within that thickness. The elastic modulii are in the range from about 28 Mpsi to about 60 Mpsi. Optionally, there is also a plurality of carbon content profiles.

Abstract: A process for diffusion bonding a coating of Nitinol intermetallic compound to a surface of a metallic substrate includes heating and cleaning the surface of the substrate to a metallurgically clean condition by creating a plasma arc in a plasmatron and partially ionizing and heating a stream of inert gas in the plasma arc. The stream of partially ionized gas from the plasmatron is directed to the surface of the substrate to remove oxides and other contaminants from the surface. Nitinol powder is entrained in a mixture of hydrogen and argon gasses heated and ionized in the plasmatron, thereby heating the powder to a partially molten state. The partially molten power is ejected in the gas mixture from the plasmatron at high velocity and impacts against the metallurgically clean heated substrate surface to produce a diffusion bond between the Nitinol intermetallic compound and the metal substrate.

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: This invention relates to methods whereby reprocessed nanoparticle powder feeds, nanoparticle liquid suspensions, and metalorganic liquids are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. In one embodiment of this invention, the nanostructured feeds consist of spherical agglomerates produced by reprocessing as-synthesized nanostructured powders. The method is applicable to as-synthesized nanostructured powders made by a variety of liquid chemical processing methods. In another embodiment of this invention, a fine dispersion of nanoparticles is directly injected into a combustion flame or plasma thermal spray device to form high-quality nanostructured coatings.

Abstract: A method of defining valve seats on valve seat supports of an internal combustion engine head. The method includes steps of; (a) roughening the exposed surface of the valve seat support to a finish of 10-50 .mu.m RA; (b) thermally spraying a stream of composite particles onto the roughened support surface, using gaseous propellants with sufficient heat and force to produce a dense adherent composite coating of metal and metal oxide particles and to a thickness no greater than 1-1.5 mm; and (c) finish machining if necessary, the sprayed coating to define the valve seat surface. The composite coated product consists of a metal/metal oxide mixture that possesses one or more of the following characteristics: a surface porosity of 2-5%, a density of 6.5-8 grams/cc, a Vickers hardness of about 280 kg/mm.sup.2 at 450.degree. C., high wear resistance and high corrosion resistance.

Abstract: An apparatus for forming a film on a substrate includes a gas inlet and an insert attached to the gas inlet, the insert including a deposition source material such as lithium. To form the film on the substrate, the substrate is mounted in a vacuum chamber. After the vacuum chamber is pumped clown to a subatmospheric pressure, a first process gas such as argon is provided through the gas inlet and insert and into a plasma region proximate the substrate. Power is then coupled to generate a plasma inside of the insert which heats the insert and causes the deposition source material to vaporize. The deposition source material vapor is mixed with a plasma polymerizable material in the plasma region proximate the substrate causing a plasma enhanced chemical vapor deposition (PECVD) thin film such as silicon oxide including the deposition source material (e.g. lithium) to be deposited on the substrate.

Abstract: A process for the deposition of thick coatings with a thickness >1 mm on products made of copper or alloys thereof, wherein said products are subjected to the following operations: surface activation of the product made of copper or alloys thereof; optional heat stabilization to a temperature below the ones causing deterioration of the chemical and physical properties of the copper or alloys thereof; deposition of a first layer, for example of Ni or alloys thereof; optional interdiffusion heat treatment; optional activation of the surface of the first layer; thermal stabilization of said product at a temperature of between 20.degree. and 400.degree. C.

Abstract: A protective coating for protecting a component from corrosion and oxidation at a high temperature and from excessive thermal stress, has a heat insulation layer including a ceramic material and an adhesion-promoting layer including a rhenium containing metal alloy. The metal alloy belongs to the alloys covered by the general term MCrAlY, where M represents cobalt and/or nickel and Y represents yttrium and/or at least one equivalent metal from the group including scandium and the rare earth elements. The protective coating is distinguished by high oxidation resistance and corrosion resistance of the alloy, by outstanding thermal fatigue properties and an effective and permanent bond between the alloy and the ceramic heat insulation layer. As a result of the heat insulation, the temperature at the outer surface of the protective coating can be considerably higher than with purely metallic protective coatings, without an increased thermal load being exerted on the component.

Abstract: A method of fusing a thermal spray coating to a base material employs infrared heating. The thermal spray coating is applied to the base material in a conventional manner. The infrared heater applies unidirectional heat in a first time-temperature relation to the coating during a fusing phase to melt individual coating platelets into a dense layer and to metallurgically bond the coating to the base material. In a base material that is heat treatable, the base material can be heat treated subsequent to the fusing phase. Initial heat treating of the base material occurs during the fusing phase. Continued heat treating of the base material is achieved after the thermal spray coating fusing phase by a second application of time-temperature from the infrared heater. A cold wall process can be used to aid in the quenching phase of the heat treating process.

Abstract: The present invention relates to a method of producing catalytic materials which comprises passing an aerosol comprising a mixture of metal powder and support through a plasma torch.

Abstract: A friction element has a base element on which a coating is applied by thermal spraying of a copper alloy. The copper alloy contains 27 to 35 wt % zinc, 4 to 6 wt % aluminum, 2 to 4 wt % nickel, 0.5 to 2 wt % titanium, and copper as the remainder, with random contaminants. The copper alloy is applied onto a base element by thermal spraying, and requires only a finish treatment by stamping to achieve good tribological properties and wear resistance that are comparable to molybdenum coatings. Alternative copper-zinc alloys can have, in particular, manganese, iron, and lead constituents.

Abstract: A process for manufacturing wear and corrosion-protected surfaces on plasticized screws for injection molding machines forms the wear-resistent layers over the entire screw surface in two steps. A laser technique is used to melt additives into the surfaces of the screw rib, flank and top as well as the screw base by high-speed flame spring with hard metallic and/or ceramic substances.

Abstract: A method of staggering reversal of thermal spray inside a cylinder bore of an internal combustion engine. The method includes the steps of thermally spraying a surface of the cylinder bore by moving a thermal spray gun along a length of the surface. The method also includes the steps of reversing a direction of travel of the thermal spray gun inside the cylinder bore at different points along the length of the surface to provide a multi-layered coating on the surface.

Abstract: A method of thermally spraying a coating onto the interior of a cylindrical surface which coating is graded between enhanced optimal machinability and enhanced wear resistance.

Abstract: A thermal spray coating method comprising producing a high speed flame from a combustion gas and spraying a thermal spray coating material powder onto the surface of a base material by using the high speed flame to form a coating on the surface of the base material. The thermal spray coating material powder is a mixed powder comprising (A) 98-70% in volume of Cu based lead bronze alloy powder and (b) 2-30% in volume of Al powder or Al based alloy powder.

Abstract: A cobalt based coating is provided which is functional to reduce the coefficient of friction between two operatively, frictionally engaging titanium alloy surfaces.

Abstract: A method of protecting reinforced concrete structures comprising of applying a protective cathodic coating containing a non-corroding metal and an electrochemically active material on concrete wherein the protective coating is formed by thermally spraying a mixture of said non-corroding metal such as a valve metal and said electrochemically active material. The coating may also be formed by applying a precursor of the electrochemically active material and a metal-containing layer to concrete, then anodically polarizing said metal layer to convert the precursor into an electrochemically active material.

Abstract: This invention consists of a coating that is zebra mussel resistant and biofouling resistant without dependence on copper leaching. The coating is a solid solution of copper and nickel containing at least 65 percent copper. Application of the coating to stationary screens, traveling water screens, trash racks, louvers, and other components of water withdrawal and hydroelectric systems, netting and other porous materials used in barrier nets, fish nets, aquaculture, and fish hatcheries, the bottoms of water craft including recreational craft, boats, and ships and on bouys, piers and pilings and other materials that might benefit from resistance to the attachment of zebra mussels and other aquatic or marine organisms.

Abstract: A hardfacing apparatus includes a deposition head including a heat source, a hardfacing material source, and a chill block having a chill block surface. The deposition head is positioned at a location so as to deposit a mass of the hardfacing material onto the workpiece surface. The chill block is positioned remote from the deposition head with the chill block surface in a facing-but-spaced-apart relation to the workpiece surface, separated from the workpiece surface by a gap having a dimension between the chill block and the workpiece surface of a standoff distance D.sub.S. Molten hardfacing material is deposited onto the workpiece surface from the deposition head. Simultaneously, the workpiece surface is moved relative to the hardfacing apparatus so that the molten hardfacing material passes into the gap and is molten as it enters the gap.

Abstract: A metallic backing layer such as steel covered by a functional layer of AlSn, AlPb, CuPb, CuSn or CuZn, applied by spraying in air, and a softer covering layer applied to the functional layer by chemical or electrolytic deposition exhibits improved corrosion resistance, running-in behavior and conformability.

Abstract: A method of eliminating unevenness in pass-reversal thermal spraying of a substrate surface by: uniformly thermally spraying a substrate surface by moving a wire fed arc spray gun along the length of the substrate surface at constant spray parameters while using a first wire feed rate and a first current level for the gun's power supply; (b) when said spray gun approaches an end zone of the pass length requiring reversal of spray gun movement, reducing the wire feed rate and current by up to about 25% until the spray gun has completed such reversal and has exited from said end zone in the opposite direction; (c) while still continuing thermal spraying, restoring the wire feed rage and current to said first levels; and (d) repeating steps (b) and (c) as the spray gun approaches other or repeated end zones of the substrate length during repeated passes.

Abstract: An improved method for providing a protective coating on a metal-based substrate is disclosed. It involves the following steps:(a) applying a rough, oxidizable metallic bond layer over the substrate;(b) applying an intermediate layer of alumina over the metallic bond layer by chemical vapor deposition; and then(c) applying a zirconia-based thermal barrier coating over the intermediate layer by a plasma spray technique.The intermediate layer conforms to the bond layer and chemically isolates the bond layer from the thermal barrier coating. The metal-based substrate is often made from a superalloy.

Abstract: The present invention relates to a thermal barrier coated article with spallation and delamination inhibiting metallic bond coat. The metallic bond coat contains a reactive element oxide, preferably yttria, which reacts with sulfur, typically migrating from the substrate to the thermal barrier coating, to prevent the sulfur from inducing spallation of the oxide scale at the interface of the thermal barrier coating and the metallic bond coat. This metallic bond coat is preferably multi-layered having a reactive element oxide containing layer sandwiched between two reactive element oxide-free layers.

Abstract: A method of producing a coating layer on a localized area of a superalloy component comprises the steps of:a) producing a coating layer element with specific functional properties;b) depositing on at least one surface of the coating layer element a uniform layer obtained from a powder mixture consisting of a powder of a nickel or cobalt superalloy and a powder of a brazing filler metal;c) brazing the coated composite coating layer element obtained from step (b) on to the localized area of the component; and,d) machine finishing the component.

Abstract: A composite structure including a substrate and a heat protection element on the substrate, wherein the heat protection element includes a quasicrystalline aluminum alloy of one or a number of quasicrystalline phases which are either quasicrystalline phases in the strict sense, or approximating phases, wherein the quasicrystalline phases exhibit a thermal diffusivity, measured at ambient temperature, lower than 2.5.times.10.sup.-6 m.sup.2 /s, and a thermal diffusivity measured in the temperature range 650.degree.-750.degree. C. which does not exceed the thermal diffusivity measured at ambient temperature by more than a factor of 3, and wherein the quasicrystalline aluminum alloy comprises Al.sub.a Pd.sub.b Mn.sub.c X.sub.d Y.sub.e T.sub.f I.sub.

Abstract: A high temperature thermal sprayable material, such as a metal or metal oxide, is adhered to the surface of a thermal sprayable plastic particle to form a cladding layer thereon. The high temperature material cladding layer provides a thermal barrier that allows use of the plastic in a high temperature thermal spray process to create a duplex coating containing plastic.

Abstract: A carbon coated metal powder depositable by thermal spray techniques to form a metal coating is disclosed. The carbon coated metal powder has a composition comprising a metal powder and carbon adhered to the metal powder. The metal powder is coated with carbon to form a carbon coated metal powder. The carbon coated metal powder, after being thermally sprayed on to a substrate and after being formed into a metal coating on the substrate, has an oxygen content at least 20% by weight less than the oxygen content in the carbon coated metal powder prior to being thermally sprayed.

Abstract: A process for controllably applying thermal spray coating onto substrates is described. The process includes positioning rotor blades in a fixture rotatable about an axis, forming a spray of particles of softened coating medium in an apparatus for propelling the coating medium towards the blade tips and coating the blade tips by passing the blades through the spray of particles of coating medium. Various process details, including process parameters, are developed.

Abstract: A wear-resistant hardfacing and a method for applying such a hardfacing is taught herein. A finely powdered, wear-resistant alloy and a polyvinyl alcohol (PVA) solution slurry is coated onto the metal surface of a tool, implement, or similar item to be hardfaced. Alternatively, a binding coating of PVA solution may be applied to the metal surface followed by application of a layer of a powdered alloy. After the slurry or PVA binding coating has dried, leaving a dry coat of alloy in a PVA matrix, the metal surface is heated to the fusion temperature of the alloy in vacuum, in an inert gas atmosphere, or in hydrogen atmosphere. The metal item with the fused coating is heat treated to impart desired mechanical properties to the part substrate material. The method of the present invention gives a smooth, dense coating of the wear-resistant hardfacing without nonmetallic inclusions.

Abstract: In order to enhance the seizure resistance of a swash plate, which is the sliding part of a swash-plate type compressor, copper alloy is flame-sprayed on the swash plate. Depending upon the necessity, the following control of structure/composition: (a) a mixed structure is provided such that atomized bronze powder, which is melted during flame spraying, and an unmelted atomized structure are mixed; (b) Pb is not contained or contained slightly in the melted structure: (c) Sn, P, Al, Ag, Si, Mn, Cr, Ni, Zn, Pb and/or Bi is added to the copper; (d) hard matters are added to copper alloy; and, (e) an intermediate layer of Ni or the like is formed between the flame-sprayed layer and the substrate, is carried out.

Abstract: A method for applying a rough slip resistant non-skid surface to a substrate in the field at the cite of use, comprising applying at least one base coat of metal to a surface of the substrate; wetting the surface of the substrate with a surfactant; spreading grit onto the wetted surface of the substrate; applying at least one bond coat of metal over the grit and the substrate, locking the grit in place; and, applying at least one finish coat of metal over the grit and the substrate.

Abstract: A method for producing an atomized powder of chromium carbide particles dispersed in a nickel chromium matrix in which chromium in the powder is from 55 to 92 weight percent of the powder.

Abstract: A process for producing a coating on the surface of a plastifier screw for injection molding machines includes applying to a hard-metallic or ceramic substrate with low distortion, a steel screw base element, by high-speed flame spraying. During the coating process, a spray jet treats the different surface regions of the screw base element including the flanks and top of a rib as well as the base of the screw, independently.

Abstract: A system for protecting sections of pipe or tubing from corrosion includes depositing a continuous, low-porosity, non-corrosive, metallized layer within the end portions of a section of pipe or tubing and on its end walls.

Abstract: This invention is relating to a sputter cathode (1) with a layer of material that is applied to a substrate by sputtering, wherein this layer (3) contains low electrical conductivity particles (3a) of which a certain quantity are at least coated by a film (3b) of electrically conductive material, or which form an aggregate with a conductive material, so as to give this layer (3) sufficient electrical conductivity to be able to be applied to the substrate by means of sputtering.

Abstract: A process for treating a high temperature corrosion resistant composite surface is disclosed. The process includes the steps of forming a first alloy layer by coating a metallic base material with a NiCr alloy or a MCrAlY alloy (M being made of one or more selected from the group consisting of Fe, Ni and Co) with low pressure plasma spraying, forming a second alloy layer on the first alloy layer by coating the first layer with an alloy having identical composition with atmospheric plasma spraying and then subjecting these layers to thermal diffusion treatment in a vacuum furnace or an inert gas atmosphere furnace. Thus, high temperature corrosion resistance is provided for a metallic material used at high temperatures.

Abstract: A ceramic coated heat-resistant element comprises a heat resisting alloy base mainly composed of Ni and/or Co and a heat-resistant coating layer provided on the surface of the base and is characterized in that said heat-resistant coating layer comprises a metal layer of an alloy superior to the base in high-temperature corrosion and oxidation resistance and provided on the base, an Al.sub.2 O.sub.3 ceramic thin film layer provided on the metal layer, a ZrO.sub.2 ceramic coating layer having dense texture provided on the Al.sub.2 O.sub.3 ceramic thin film layer and a ZrO.sub.2 ceramic coating layer having columnar texture provided on the ZrO.sub.2 ceramic coating layer having dense texture cracks are present only in the ZrO.sub.2 ceramic coating layer having columnar texture in the direction of thickness along the boundary of the columns. A mixed layer composed of a metal superior to the base in high-temperature corrosion and oxidation resistance and a ZrO.sub.

Abstract: Abrasion-wear resistant thermal sprayed stainless steel based coatings are disclosed, particularly arc sprayed stainless steel coatings containing titanium diboride crystals which impart hardness to the soft stainless steel matrix and enhance their resistance to hard abrasive media. There is also disclosed a process for making core wires composed of stainless steel sheaths and cores composed of a mixture of titanium diboride, stainless steel and certain additives. During the thermal spraying operation, the stainless steel sheath and the core material melt to form a composite coating containing fine hard titanium boride crystals dispersed within stainless steel. The arc sprayed stainless steel based coatings are more resistant to abrasion wear than solid pieces of type 304 stainless steel and other arc-sprayed stainless steel-based coatings available on the market.

Abstract: A TiB.sub.2 -M coating which consists of greater than 50 vol % TiB.sub.2 hard phase particles in a metal or metal alloy (M) matrix that is produced by a thermal spray process using sintered TiB.sub.2 -M powders. The TiB.sub.2 -M powders were fabricated by sintering TiB.sub.2 powders and elemental metals or metal alloys which were selected to form a desired matrix for the TiB.sub.2 particles.