Abstract: An electrode for an electrochemical cell is presented which comprises a substrate and an electrode material. The electrode material comprises an electrocatalyst and a solid glass phase which binds the electrocatalyst to the substrate. The electrodes of the invention are durable and can be produced by a much simpler, faster technique than is required for preparing conventional electrodes and can incorporate a wider range of electrocatalytic materials.

Abstract: A method of forming a polyanion active material that includes providing a carbon source, providing a mobile ion source, providing an active metal material, providing a network material, providing a flux material, and mixing the various materials. In one aspect, the mixing step may include grinding or pulverizing materials to a uniform fine mixture. In one aspect, a ball mill may be utilized to mix the components. Following the mixing of the materials, the mixture is heated to a predetermined temperature in a non-oxidizing atmosphere to form a reaction product. In one aspect, the mixture is heated to a temperature above a melting temperature of the flux material. In this manner, the flux material provides a medium in which the various reactants may react to form the desired reaction product. Following the heating of the mixture the reaction product is washed, forming a carbon coated polyanion active material.

Abstract: Coating systems for components of a gas turbine engine, such as a compressor case, are provided. The coating system can include a dense layer disposed along the inner surface of the compressor case as well as an abradable, top coat disposed along the dense layer. The combination of dense layer and abradable top coat can reduce the occurrence of galvanic corrosion of the coating system and thereby increase the lifetime of the coating system and preserve blade clearances within the compressor. Methods are also provided for applying the coating system onto a compressor case.

Abstract: Powder of particles, more than 95% by number of said particles exhibiting a circularity greater than or equal to 0.85, wherein said powder contains more than 99.8% of a rare earth oxide and/or of hafnium oxide and/or of yttrium aluminum oxide, as percentage by weight relative to the oxides, and has: a median particle size D 50 of between 10 and 40 microns and a size dispersion index (D 90?D 10)/D 50 of less than 3; a percentage by number of particles having a size less than or equal to 5 ?m which is less than 5%; an apparent-density dispersion index (P<50?P)/P of less than 0.

Abstract: A method of forming a coating layer, including preparing hollow inorganic particles, each hollow inorganic particle including a shell surrounding a hollow core; preparing inorganic coating particles of a solid structure; forming a mixture of the hollow inorganic particles and the inorganic coating particles; and spraying the mixture on a surface of a base by a plasma spray coating process.

Abstract: A method includes feeding powder comprising a yttrium oxide into a plasma spraying system, wherein the powder comprises a majority of donut-shaped particles, each of the donut-shaped particles having a spherical body with indentations on opposite sides of the spherical body. The method further includes plasma spray coating an article to apply a ceramic coating onto the article, wherein the ceramic coating comprises the yttrium oxide, wherein the donut-shaped particles cause the ceramic coating to have an improved morphology and a decreased porosity as compared to powder particles of other shapes, wherein the improved surface morphology comprises a reduced amount of surface nodules.

Abstract: A heat-resistant member includes a member that is a target to be protected and a protective layer arranged on the whole or part of a surface of the member. The protective layer includes an oxide ceramic containing an Fe3O4 phase in which a solute component capable of forming a spinel-type oxide with Fe is solid-dissolved.

Abstract: A fabrication process for production of planar type solid oxide fuel cell with high electrical conductivity and low fuel gas impedance is disclosed. It is a tape casting to produce an anode substrate furnished with a pore array structure on one or plurality of layers of the anode green tape on the utmost outside of the anode. It is to implement the process of solid oxide fuel cell membrane electrode assembly (SOFC-MEA) with precision abrasion to remove nickel depleted layer on the anode surface to complete the production of a unit cell. The fabrication of anode with pore array structure provides a good conduction effect for fuel gas and the solid oxide fuel cell with this treatment has features of high electrical conductivity and low fuel gas impedance to improve the performance of SOFC unit cell.

Abstract: Methods are provided for modifying a transparent and electrically conductive metal-oxide coating deposited on a plastic substrate. At least one surface region of the metal oxide coating is impinged by a pulse-driven electron beam. The impingement of the surface region of the metal oxide coating by the pulse-driven electron beam occurs inside a vacuum chamber into which hydrogen, argon, nitrogen, or oxygen, or a gas mixture of at least two of the above-mentioned gasses has been introduced.

Abstract: Silicon deposited by CVD and/or silico dust is removed from a polycrystalline silicon deposition reactor component by abrasion with silicon-containing particles in a gas stream.

Abstract: A process for forming a ceramic coating on a substrate, such as a turbine engine component includes the steps of providing a substrate, creating a plasma which preheats the substrate, and forming a ceramic coating by injecting a powder feedstock into the plasma. The ceramic coating forming step comprises depositing ceramic particles having a mean size in the range of from 100 to 150 microns at constant particle morphology.

Abstract: A photocatalytic film structure is provided. The photocatalytic film includes a plurality of micron particles; a plurality of nano particles; and a plurality of block bodies, wherein the volume of each of the block bodies is greater than that of each of the nano particles, and each of the micron particles, the nano particles and the block bodies contains zinc oxide and a doping metal, and wherein the amount of the doping metal is 1 to 5 wt % of the photocatalytic film, and the plurality of micron particles and micron particles take up 10 to 50% of the volume of the photocatalytic film.

Abstract: A method for preparing an electrolyte separator for an electrochemical device is described. The method includes the step of applying a beta?-alumina coating composition, or a precursor thereof, to a porous substrate, by an atmospheric, thermal spray technique. An electrochemical device is also described. Some of these devices include an anode, a cathode, and an electrolyte separator disposed between the anode and the cathode. The separator includes a thermally-sprayed layer of beta?-alumina, disposed on a porous substrate. The electrochemical device can be used as an energy storage system, or for other types of end uses.

Abstract: An article and method of forming the article are disclosed. The article includes a substrate, an overlay bond coat deposited over the substrate and a topcoat deposited over the bond coat. The bond coat of the article includes a plasma affected region proximate to an interface between the bond coat and the topcoat, and the plasma affected region includes an elongated intergranular phase. The method of depositing includes adjusting the plasma spray conditions so as to form the plasma affected region proximate to an interface between the bond coat and the topcoat, and elongated intergranular phases in the plasma affected regions.

Abstract: An article includes a substrate with a coating having asperities such that an average spacing between the asperities is between about 0.01 and about 1.5 micron. An average surface roughness of the coating is up to about 2 microns, and an average porosity of the coating is in the range from about 35% to about 70%. A material to reduce surface energy is disposed on the coating. A method for making such an article and a method for decreasing fluid drag across such an article are also provided.

Abstract: To apply a thermal barrier coating (10), a plasma jet (5) is generated by a plasma torch in a work chamber (2) and is directed to the surface of a substrate (3) introduced into the work chamber, and a ceramic coating material is applied to the substrate surface by means of PS-PVD, wherein the coating material is injected into the plasma jet as a powder and is partly or completely vaporized there. On applying the thermal barrier coating, in a first workstep the feed rate of the injected powder is set so that a large part of the injected powder vaporizes, wherein the coating material condenses from the vapor phase on the substrate surface and forms mixed phases with the material of the substrate surface.

Abstract: Methods for improving surface roughness of an environmental barrier coating. The methods include providing a component having a plasma sprayed environmental barrier coating, applying an outer layer repair slurry to the environmental barrier coating of the component, drying the environmental barrier coating having the applied outer layer repair slurry, and sintering the component to produce a component having an improved surface roughness. The outer layer repair slurry includes water, a primary outer material of BSAS, and a slurry sintering aid selected from rare earth nitrate, rare earth acetate, rare earth chloride, rare earth oxide, ammonium phosphate, phosphoric acid, polyvinyl phosphonic acid, and combinations thereof.

Abstract: A method for forming a plasma resistant ceramic coating on an article includes placing the article into a chamber or spray cell of a plasma spraying system. A ceramic powder is then fed into the plasma spraying system at a powder feed rate, and a plasma resistant ceramic coating is deposited onto at least one surface of the article in a plasma spray process by the plasma spray system. The plasma spray system is then used to perform an in-situ plasma flame heat treatment of the plasma resistant ceramic coating to form crust on the plasma resistant ceramic coating.

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 coating material for a thermal spray coating having corrosion resistance and low reactivity, a preparation method thereof, and a coating method thereof are provided. The coating material for thermal spray coating has a composition of Mg1?xY2xO2x+1 (where x is 0.01 to 0.99).

Abstract: Disclosed are, inter alia, methods of forming coated substrates for use in catalytic converters, as well as washcoat compositions and methods suitable for using in preparation of the coated substrates, and the coated substrates formed thereby. The catalytic material is prepared by a plasma-based method, yielding catalytic material with a lower tendency to migrate on support at high temperatures, and thus less prone to catalyst aging after prolonged use. Also disclosed are catalytic converters using the coated substrates, which have favorable properties as compared to catalytic converters using catalysts deposited on substrates using solution chemistry. Also disclosed are exhaust treatment systems, and vehicles, such as diesel vehicles, particularly light-duty diesel vehicles, using catalytic converters and exhaust treatment systems using the coated substrates.

Abstract: The invention relates to a method for producing a ceramic layer (18) on a surface formed from a Ni base alloy (17), comprising the following steps: producing on the surface a ceramic layer (18) containing ZrO2 as a main constituent; producing a gas phase having a temperature in the range from 400 to 900° C., in which a vapour formed from a salt melt (8) with the components alkali chloride, alkali sulphate and ZnCl2 is contained in a carrier gas formed from an inert gas with an addition from 0.5 to 10% by weight HCl; and bringing the ceramic layer (18) into contact with the gas phase for a period of time that is sufficient for an intermediate layer (19) having a thickness of at least 0.1 ?m to form between the ceramic layer (18) and the surface.

Abstract: Compositions and method for preparing thermally sprayed coatings are disclosed. The inventive compositions include at least one component that is electrically-insulating and/or non-subliming at thermal spray temperatures; and at least one component that has a high coefficient of thermal expansion. The invention also provides a compositions and methods for preparing a coating comprising a spinel, from materials that do not comprise a spinel; and also provides non-spinel materials used to prepare coatings comprising spinel. The invention includes coatings made from the materials and methods; and articles comprising the coatings.

Abstract: A thermal barrier coating that includes a YAG-based ceramic is prepared by a solution precursor plasma spray method that includes injecting a precursor solution into a thermal jet, evaporating solvent from the precursor solution droplets, and pyrolyzing the resulting solid to form a YAG-based ceramic that is melted and deposited on a substrate. The thermal barrier coating can include through-coating-thickness cracks that improve the strain tolerance of the coating.

Abstract: Substrate structure comprising a substrate (6) and a plasma grown layer (6a). The surface of the resulting substrate structure (7) is characterized by interrelated scaling components. The scaling components comprise a roughness exponent ?, a growth exponent ? and a dynamic exponent z, wherein the growth exponent ? has a value of less than 0.2 and the dynamic exponent z has a value of more than 6. Also disclosed is a method to provide such a substrate structure.

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: An infrared ray cut-off material is formed of phosphorus-doped antimony tin oxide powder, in which a content of antimony in terms of SbO2 is not less than 14 parts by mass and not more than 30 parts by mass with respect to 100 parts by mass of the infrared ray cut-off material, a content of phosphorus in terms of PO2.5 is not less than 1 part by mass and not more than 25 parts by mass with respect to 100 parts by mass of the infrared ray cut-off material, and a balance other than antinomy oxide and phosphorus oxide is tin oxide.

Abstract: A method of smoothing the surface of a ceramic matrix composite material part that presents a surface that is undulating and rough. The method includes depositing a refractory vitreous coating on the surface of the part, the vitreous coating essentially containing silica, alumina, baryte, and lime.

Abstract: A process for preparing a ceramic body having a surface roughness, said process comprising the step of depositing particles of a ceramic material on the surface of a ceramic basic body. The process is characterized in that separate agglomerates comprising at least two particles and a binder binding the particles together are deposited on the surface of the basic body by projecting the agglomerates towards the basic body.

Abstract: An article includes a body that is coated with a ceramic coating. The ceramic coating may include Y2O3 in a range between about 45 mol % to about 99 mol %, ZrO2 in a range between about 0 mol % to about 55 mol %, and Al2O3 in a range between about 0 mol % to about 10 mol %. The ceramic coating may alternatively include Y2O3 in a range between about 30 mol % to about 60 mol %, ZrO2 in a range between about 0 mol % to about 20 mol %, and Al2O3 in a range between about 30 mol % to about 60 mol %.

Abstract: An yttrium oxide coating has a porosity of 1.5% or less and contains monoclinic yttrium oxide at a ratio of 1% or more and 30% or less to the sum of monoclinic yttrium oxide and cubic yttrium oxide in the coating. The coating is formed, for example, by thermal spraying a thermal spraying material containing yttrium oxide particles and a dispersion medium.

Abstract: In a film-forming treatment jig for forming a thin film on a plate having a through hole of a micro diameter by a single plasma film-forming treatment, the film-forming treatment jig includes: a holding member 39 for holding the aperture plate in a state of exposing the through hole and the front and back surfaces of the aperture plate by clamping an aperture plate 107 having a through hole; and an electrode member having the holding member attached thereon, wherein the electrode member is electrically connected to an electrode to which the plasma electric power of a plasma CVD apparatus is applied.

Abstract: A method to improve corrosion, abrasion, and fire resistant properties of structural components for use in oil, gas, exploration, refining and petrochemical applications is provided. The structural component is suitable for as refinery and/or petrochemical process equipment and piping, include but are not limited to process vessels, transfer lines and process pipes, heat exchangers, cyclones, and distillation columns. The method comprises providing the structural component with a plurality of layers, a corrosion resistant layer in contact with the corrosive petroleum products comprising a material selected from amorphous metals, ceramic materials, or combinations thereof; a structural layer; and an outer layer comprising a fire resistive material. In one embodiment, the structural component is further provided with at least another layer selected from a metal sheeting layer, an adhesive layer, and a containment layer.

Abstract: A plasma spray method for the manufacture of an ion conductive membrane is provided which ion conductive membrane has an ion conductivity, in which method the membrane is deposited as a layer (11) onto a substrate (10) in a process chamber, wherein a starting material (P) is sprayed onto a surface of the substrate (10) in the form of a process beam (2) by means of a process gas (G), wherein the starting material is injected into a plasma at a low process pressure, which is at most 10,000 Pa, and is partially or completely molten there. Oxygen (O2; 22) is supplied to the process chamber (12) during the spraying at a flow rate which amounts to at least 1%, preferably at least 2%, of the overall flow rate of the process gas.

Abstract: A substrate mounting table includes a plate shaped member provided with a mounting surface for mounting a substrate thereon, a plurality of gas injection openings opened on the mounting surface to supply a gas toward the mounting surface, and a gas supply channel for supplying the gas through the gas injection openings; and a thermally sprayed ceramic layer covering the mounting surface. At least inner wall portions of the gas supply channel are formed in curved surface shapes, the inner wall portions facing the gas injection openings.

Abstract: A method for fabricating thermal barrier coatings. The thermal barrier coatings are produced with a fine grain size by reverse co-precipitation of fine powders. The powders are then sprayed by a solution plasma spray that partially melts the fine powders while producing a fine grain size with dense vertical cracking. The coatings comprise at least one of 45%-65% Yb2O3 the balance Zr, Yb/Y/Hf/Ta the balance Zr and 2.3-7.8% La, 1.4-5.1% Y and the balance Zr and are characterized by a thermal conductivity that is about 25-50% lower than that of thermal barrier coatings comprising YSZ. The thermal barrier coatings also are characterized by at least one of excellent erosion resistance, fracture toughness and abrasion resistance.

Abstract: An automated hydrogen bubble detection apparatus includes a horizontal support surface on which a test coupon can be supported, a transparent tube having an open top and an open bottom and operable to contain a test solution when positioned on a test coupon, a camera arranged to view a test solution in the transparent tube, and a controller in communication with the camera and effective to operate the camera such that at least one video segment is recorded by the camera and analyzed to detect first bubble and continuous bubble generation. A method of evaluating corrosion resistance of coatings on aluminum and steel in acidic solution is also included.

Abstract: A high strength composite particle comprised of a series of incrementally applied resin microlayer coatings such that each of the microlayer partial coatings are interleaved with each other is described. Methods of making the composite particles, as well as methods of using such particles as a proppant in oil and gas well hydraulic fracturing are also described.

Abstract: Combustion deposition systems and methods of using combustion deposition systems are disclosed. In an embodiment, a combustion deposition system may include a burner that is in fluid communication with at least one supply of at least one precursor such that the at least one precursor can be introduced to a flame output from the burner, at least one electrode positioned at least proximate to the flame, and a voltage source operably coupled to the at least one electrode. The at least one electrode and the at least one voltage source may be configured to generate an electric field for influencing at least one of flame shape, flame temperature, or kinetics of chemical reactions occurring within the flame, thereby providing enhanced selective control of combustion deposition characteristics. For example, the combustion deposition systems disclosed herein may, for example, be configured to control deposition of a combustion-deposited film on a substrate.

Abstract: A method of cleaning a carbon work piece includes the step of applying an acetone cleaning agent to the carbon work piece to remove debris therefrom. The removal of debris promotes adhesion between the carbon work piece and a subsequently applied coating. For example, other steps may precede the acetone cleaning step, such as submersing the carbon work piece in deionized water. In one example, a subsequent coating process deposits an alumina coating on the carbon work piece.

Abstract: Embodiments of the present invention generally relate to heated substrate supports having a protective coating thereon. The protective coating is formed from yttrium oxide at a molar concentration ranging from about 50 mole percent to about 75 mole percent; zirconium oxide at a molar concentration ranging from about 10 mole percent to about 30 mole percent; and at least one other component, selected from the group consisting of aluminum oxide, hafnium oxide, scandium oxide, neodymium oxide, niobium oxide, samarium oxide, ytterbium oxide, erbium oxide, cerium oxide, and combinations thereof, at a molar concentration ranging from about 10 mole percent to about 30 mole percent. The alloying of yttrium oxide with a compatible oxide improves wear resistance, flexural strength, and fracture toughness of the protective coating, relative to pure yttrium oxide.

Abstract: A high temperature thermal barrier coating which consists of a stabilized ZrO2 composition for the protection of thermally loaded components (10, 10?) of a thermal machine, especially a gas turbine, is disclosed. The thermal barrier coating is stabilized with at least 15 mol % Y1+v Ta1?vO4?v, the ZrO2 is partially substituted by at least 10 mol % HfO2 and the composition is established according to the formula (Y1+vTa1?vO4?v)z(Zr1?xHfxO2)1?z, with x ranging from 0.1 to 0.5, v ranging from ?0.1 to 0.2 and z ranging from 0.15 to 0.25.

Abstract: A method of preparing nanostructured zinc oxide layers on a substrate by chemical spray pyrolysis at moderate deposition temperatures from 350.degree. C. to 600.degree. C. is disclosed. An aqueous or aqueous alcoholic solution comprising zinc chloride or zinc acetate as precursors is prepared and sprayed onto the preheated substrate so that the precursor reacts to form zinc oxide layer on the substrate. Thiourea or urea may be also added to the solution. Glass, silicon, or metal oxide covered glass can be used as the substrate.

Abstract: Disclosed are a transparent conductive substrate comprising a transparent conductive thin film layer and a transparent metal oxide layer disposed in this order on one or both surfaces of a substrate, the transparent metal oxide layer having numerous fine pores penetrating from the front surface to the rear surface thereof, and the pore diameters of the pores at the surface that is opposite to the surface that is in contact with the transparent conductive thin film layer being larger than those at the surface that is in contact with the transparent conductive thin film layer; and a method for producing the transparent conductive substrate, comprising forming the transparent metal oxide layer on the surface of the transparent conductive thin film layer or transparent conductive thin film layers by oblique deposition.

Abstract: A durable ceramic and metallic coating has been applied to ceramic tiles to protect the tiles while undergoing a molten metal casting operation. The plasma sprayed coating consists of a ceramic top coat layer of aluminum oxide, zirconium oxide, or other oxides with or without a metallic bond coat layer and with or without a functionally gradient coating. This coating protects the underlying ceramic tile, which is composed of boron carbide, silicon carbide, alumina (Al2O3) or other type of hard ceramic, from reacting chemically with the molten metal. The molten metal is cast around the ceramic tiles to create a lattice of ceramic tiles that are used for protection from projectiles and shrapnel.

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: Angular sectors of a cylindrical wall of a crucible for vitrification of waste, built in steel and subject to high temperatures, are coated with a mixture of mainly glass and ceramic, the coating being subject to a heat treatment comprising a step between 650° C. and 850° C. so as to perform surface melting of the mixture filling the open porosity, improving dielectric strength and the cohesion of the coating, but without producing any excessive thermal expansion or oxidation of the substrate which would lead to fast flaking of the coating.

Abstract: A cooking utensil and a manufacturing method thereof are provided. The cooking utensil includes a cooking body, a first metal-ceramic composite layer having an electromagnetic property and a second metal-ceramic composite layer having a heat conductive property. The cooking body has an external bottom surface. The first metal-ceramic composite layer is disposed on the external bottom surface of the cooking body. The second metal-ceramic composite layer is disposed on the first metal-ceramic composite layer. The cooking utensil is suitable for both an induction cooker and a gas burner.

Abstract: This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

Abstract: A method for manufacturing enamel layer includes the steps of: a substrate is provided; a spray paint is provided, the spray paint includes liquid fuel and enamel powders; providing a spraying device for spraying the spray paint, the liquid fuel of the spray paint spayed by the spraying device fires to heat and sinter the enamel powder to deposit on the substrate and form the enamel layer. The article manufactured by the method is also provided.