Method of coating metallic powder particles

A method and system for coating metallic powder particles is provided. The method includes: disposing an amount of metallic powder particulates within a fluidizing reactor; removing moisture adhered to the powder particles disposed within the reactor using a working gas; coating the powder particles disposed within the reactor using a precursor gas; and purging the precursor gas from the reactor using the working gas.

ELECTRIC COMPONENT INCLUDING CUSTOM METAL GRAIN ORIENTATION

An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux. 1. An electrical device , comprising:an electromagnetic component configured to generate a magnetic flux; the electromagnetic component comprising a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path, the soft magnetically-conductive material including at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux.2. The electrical device of claim 1 , wherein the electromagnetic component includes a stator disposed adjacent a rotor that rotates with respect to the stator.3. The electrical device of claim 2 , wherein the stator comprises the soft magnetically-conductive material.4. The electrical device of claim 3 , wherein the stator comprises a transition region interposed between a plurality of stator teeth and an outer yoke portion claim 3 , wherein at least one of one or more stator teeth and the exterior yoke portion has a grain oriented metal portion.5. The electrical device of claim 4 , wherein the grain oriented metal portion has a grain orientation that substantially matches a flux orientation of the flux path.6. The electrical devices of claim 5 , wherein a first grain oriented metal portion of the stator teeth extending in direction transverse to a respective stator tooth.7. The electrical device of claim 6 , wherein a second grain oriented metal portion of the outer yoke portion has a circumferential orientation extending along a circumference of the outer yoke portion.8. The electrical device of claim 6 , wherein the transition region has a non- ...

Method of coating an iron-based article

A method of coating an iron-based article includes a first heating step of heating a substrate that includes an iron-based material in the presence of an aluminum source material and halide diffusion activator. The heating is conducted in a substantially non-oxidizing environment, to cause the formation of an aluminum-rich layer in the iron-based material. In a second heating step, the substrate that has the aluminum-rich layer is heated in an oxidizing environment to oxidize the aluminum in the aluminum-rich layer.

Powder metal with attached ceramic nanoparticles

A method for processing a powder material includes cleaning surfaces of a powder material that has spherical metal particles, coating the cleaned surfaces with an organic bonding agent, mixing the coated particles with a dispersion that contains ceramic nanoparticles, drying the mixture to remove a carrier of the dispersion and deposit the ceramic nanoparticles with a spaced-apart distribution onto the organic bonding agent on the surfaces of the particles, and thermally removing the organic bonding agent to attach the ceramic nanoparticles to the surface of the particles.

SOLID-STATE METHOD FOR FORMING AN ALLOY AND ARTICLE FORMED

A solid-state method for forming an alloy includes providing a powder that has heterogeneous particles with a ratio, by weight, of an amount of nickel to an amount of a metal. The ratio is selected in accordance with a compositional ratio that can substantially bear a nickel intermetallic precipitate of the nickel and the metal. The heterogeneous particles are then consolidated and thermally treated to interdiffuse the nickel and the metal. The interdiffused nickel and metal are then precipitation treated to precipitate the nickel intermetallic. 1. A solid-state method for forming an alloy , the method comprising:providing a powder including composite particles having a ratio, by weight, of an amount of nickel to an amount of a metal, the ratio being selected in accordance with a compositional ratio that can substantially bear a nickel intermetallic precipitate of the nickel and the metal;consolidating the composite particles of the powder;thermally treating the consolidated powder to interdiffuse the nickel and the metal; andprecipitation treating the interdiffused nickel and metal to precipitate the nickel intermetallic.2. The method as recited in claim 1 , wherein the composite particles individually include the nickel and the metal.3. The method as recited in claim 1 , wherein the ratio is 30:70 to 99:1.4. The method as recited in claim 1 , wherein the ratio is 58:42 to 62:38.5. The method as recited in claim 1 , wherein the ratio is 60:40.6. The method as recited in claim 1 , wherein the ratio nominally is +/−2% of a critical ratio for substantially bearing the nickel intermetallic precipitate.7. The method as recited in claim 1 , wherein the metal is selected from the group consisting of aluminum claim 1 , titanium claim 1 , cobalt claim 1 , iron claim 1 , boron claim 1 , chromium claim 1 , molybdenum claim 1 , niobium claim 1 , tantalum claim 1 , tungsten claim 1 , rhenium claim 1 , platinum claim 1 , zirconium claim 1 , yttrium claim 1 , hafnium claim 1 , ...

METHOD OF COATING METALLIC POWDER PARTICLES WITH SILICON

A method of coating metallic powder particles includes disposing an amount of metallic powder particles in a fluidizing reactor and removing moisture adhered to the powder particles within the reactor with a working gas at an elevated temperature for a predetermined time. The method further includes coating the powder particles in the reactor with silicon present within the precursor gas at an elevated temperature for a predetermined time and purging the precursor gas from the reactor using the working gas. 1. A method of coating metallic powder particles with silicon comprising:disposing an amount of metallic powder particulates within a fluidizing reactor;removing moisture adsorbed to the powder particles disposed within the reactor using a working gas at a temperature of from about 350° C. to about 450° C. for about 3 to 5 hours;coating the powder particles disposed within the reactor with silicon present within a precursor gas at a temperature of from about 300° C. to about 500° C. for about 0.5 hours to about 6 hours; andpurging the precursor gas from the reactor using the working gas.2. The method of claim 1 , wherein the coating includes coating the powder particles with silicon in an amount such that the coated powder particles have a level of reflectivity that is less than 30% for subsequent processing of the coated powder particles within an additive manufacturing process.3. The method of claim 1 , wherein the working gas comprises argon claim 1 , nitrogen or He.4. The method of claim 2 , wherein the metallic powder particles are aluminum alloy.5. The method of claim 4 , wherein the aluminum alloy comprises at least one of aluminum 5056 claim 4 , aluminum 6061 claim 4 , aluminum 7075 claim 4 , or PANDALLOY aluminum alloy.6. The method of claim 5 , wherein the aluminum alloy comprises aluminum 6061.7. The method of claim 1 , wherein removing moisture adsorbed to the powder particles using a working gas at an elevated temperature for a predetermined time ...

SYNTHESIS OF ALLOY AND DIFFUSION MATERIAL NANOPARTICLES

A method for preparing an alloy nanocellular foam includes at least partially coating a nanocellular precursor into a multiple composition nanoparticle precursor and converting the multiple composition nanoparticle precursor into an alloy via a diffusion process. 1. A method for preparing an alloy nanocellular foam comprising:disposing a nanoparticle precursor in an electrochemical deposition apparatus;operating said electrochemical deposition apparatus, thereby at least partially coating said nanoparticle precursor into a multiple composition nanoparticle precursor, wherein the coated nanoparticle precursor forms an alloy nanoparticle via a diffusion process conducted subsequent to the coating process;removing said converted nanoparticle precursor from said electrochemical deposition apparatus; andconstructing a nanocellular foam from said converted alloy nanoparticle precursor.2. The method of claim 1 , wherein said converted nanoparticle precursor is an alloy of nickel and the metals deposited on the precursor is at least one of aluminum (Al) claim 1 , cobalt (Co) claim 1 , chromium (Cr) claim 1 , tungsten (W) claim 1 , rhenium (Re) claim 1 , tantalum (Ta) claim 1 , hafnium (Hf) claim 1 , yttrium (Y) claim 1 , carbon (C) claim 1 , boron (B) claim 1 , zirconium (Zr).3. The method of claim 2 , wherein said alloy is an alloy of nickel and aluminum.4. The method of claim 1 , wherein disposing a nanoparticle precursor in an electrochemical deposition apparatus comprises:disposing said nanoparticle precursor in a cathode pouch made from mesh materials of said electrochemical deposition apparatus;disposing said cathode pouch in an electrolyte solution; anddisposing an anode of the electrochemical deposition apparatus in the electrolyte solution.5. The method of claim 1 , wherein disposing a nanoparticle precursor in an electrochemical deposition apparatus comprises:disposing said pure material nanoparticle precursor in a powder bed hosted in a tubular housing element of ...

METHOD OF PRODUCING A CERAMIC ARTICLE, INTERMEDIATE ARTICLE AND COMPOSITION THEREFOR

A method of producing a ceramic material includes heating solid silicon monoxide to provide gaseous silicon monoxide, and exposing a structure having a free-carbon-containing material to the gaseous silicon monoxide to convert free carbon of the free-carbon-containing material to silicon carbide. Also disclosed is an intermediate article that includes a solid structure having free carbon and a solid, in-situ source of silicon monoxide gas. Also disclosed is a composition that includes a polymeric carrier phase and particulate of solid silicon monoxide dispersed in the polymeric carrier phase. 1. A method of producing a ceramic article , the method comprising:heating solid silicon monoxide to provide gaseous silicon monoxide; andexposing a structure having a free-carbon-containing material to the gaseous silicon monoxide to convert free carbon of the free-carbon-containing material to silicon carbide.2. The method as recited in claim 1 , further comprising providing the solid silicon monoxide as a particulate dispersed in a coating on at least a portion of the structure.3. The method as recited in claim 2 , wherein the coating includes a polymeric carrier phase and the particulate of the solid silicon monoxide is dispersed in the polymeric carrier phase.4. The method as recited in claim 3 , wherein the exposing includes heating the coated structure to convert the particulate of the solid silicon monoxide in the polymeric carrier phase to the gaseous silicon monoxide.5. The method as recited in claim 3 , wherein the particulate of the solid silicon monoxide is provided in an amount that is stoichiometrically equal to or greater than the amount of free carbon.6. The method as recited in claim 3 , wherein the polymeric carrier phase is a preceramic polymer claim 3 , and further including converting the preceramic polymer phase to a ceramic material.7. The method as recited in claim 1 , wherein the free carbon is residual free carbon from a prior thermal process used to ...

AN ADDITIVE MANUFACTURING SYSTEM WITH A MULTI-ENERGY BEAM GUN AND METHOD OF OPERATION

An additive manufacturing system includes an energy gun having a plurality of energy source devices each emitting an energy beam. A primary beam melts a selected region of a substrate into a melt pool and at least one secondary beam heat-conditions the substrate proximate the melt pool to reduce workpiece internal stress and/or enhance micro-structure composition of the workpiece. 1. An energy gun of an additive manufacturing system for producing a workpiece from a substrate , the energy gun comprising:a plurality of energy beams constructed and arranged to follow one-another.2. The energy gun set forth in wherein the plurality of energy beams includes a first energy beam for producing a melt pool from the substrate and a second energy beam for post heating to control a solidification rate of the melt pool.3. The energy gun set forth in wherein the plurality of energy beams includes a first energy beam for producing a melt pool from the substrate and a second energy beam for pre-heating the substrate associated with the melt pool.4. The energy gun set forth in wherein the substrate is a powder.5. The energy gun set forth in wherein the plurality of energy beams have different frequencies.6. The energy gun set forth in further comprising:a plurality of energy source devices wherein each one of the plurality of energy source devices emits a respective one of the plurality of energy beams.7. The energy gun set forth in wherein the plurality of energy sources have fiber optic outputs.8. The energy gun set forth in wherein each one of the plurality of energy beams impart a hot spot upon the substrate at pre-arranged distances from one-another and the plurality of energy source devices are constructed and arranged to move the hot spots in unison across the substrate at a controlled velocity.9. The energy gun set forth in further comprising:a lens for focusing at least one of the plurality of energy beams.10. The energy gun set forth in wherein the plurality of energy ...

Method for synthesizing nanowires and nanofoam

A method for making a plurality of metallic nanowires includes combining a metallic precursor with a solvent to form a metallic precursor solution. A quantity of oxalic acid is added to the metallic precursor solution to form a reduction solution. A plurality of nanowires are precipitated out from the reduction solution.

METHOD OF COATING METALLIC POWDER PARTICLES

A method and system for coating metallic powder particles is provided. The method includes: disposing an amount of metallic powder particulates within a fluidizing reactor; removing moisture adhered to the powder particles disposed within the reactor using a working gas; coating the powder particles disposed within the reactor using a precursor gas; and purging the precursor gas from the reactor using the working gas.

ADDITIVE MANUFACTURING OF METAL MATRIX COMPOSITE FEEDSTOCK

A feedstock for an additive manufacturing process includes a pre-ceramic polymer intermixed with a base material. A method of additive manufacturing includes melting and pyrolizing a feedstock containing metal and a pre-ceramic polymer. An article of manufacture includes an additive manufacturing component including a pyrolized feedstock.

POWDER METAL WITH ATTACHED CERAMIC NANOPARTICLES

A method for processing a powder material includes cleaning surfaces of a powder material that has spherical metal particles, coating the cleaned surfaces with an organic bonding agent, mixing the coated particles with a dispersion that contains ceramic nanoparticles, drying the mixture to remove a carrier of the dispersion and deposit the ceramic nanoparticles with a spaced-apart distribution onto the organic bonding agent on the surfaces of the particles, and thermally removing the organic bonding agent to attach the ceramic nanoparticles to the surface of the particles. 1. A method for processing a powder material , the method comprising:cleaning surfaces of a powder material that has spherical metal particles;coating the cleaned surfaces with an organic bonding agent;mixing the coated particles with a dispersion that contains ceramic nanoparticles;drying the mixture to remove a carrier of the dispersion and to deposit the ceramic nanoparticles with a spaced-apart distribution onto the organic bonding agent on the surfaces of the spherical metal particles; andthermally removing the organic bonding agent to attach the ceramic nanoparticles to the surfaces of the spherical metal particles.2. The method as recited in claim 1 , wherein the ceramic nanoparticles are oxide nanoparticles.3. The method as recited in claim 1 , wherein the ceramic nanoparticles are zirconium oxide.4. The method as recited in claim 1 , wherein the ceramic nanoparticles are selected from the group consisting of oxides claim 1 , nitrides claim 1 , carbides claim 1 , and combinations thereof.5. The method as recited in claim 1 , wherein claim 1 , after the thermal removal of the organic bonding agent claim 1 , the powder material has a composition claim 1 , by weight claim 1 , of 0.1-5% of the ceramic nanoparticles.6. The method as recited in claim 1 , wherein the cleaning includes etching the surfaces using an acid.7. The method as recited in claim 1 , wherein after the mixing and prior to ...

Friction brake assembly with an abradable metal foam brake pad

A brake assembly and a method for manufacturing a brake assembly are provided. The brake assembly includes a brake pad affixed to a substrate. The brake pad extends from the substrate to a brake pad friction surface, and includes abradable cellular metal foam with the hardened ceramic particles.

METHOD OF COATING METALLIC POWDER PARTICLES WITH SILICON

A method of coating metallic powder particles includes disposing an amount of metallic powder particles in a fluidizing reactor and removing moisture adhered to the powder particles within the reactor with a working gas at an elevated temperature for a predetermined time. The method further includes coating the powder particles in the reactor with silicon present within the precursor gas at an elevated temperature for a predetermined time and purging the precursor gas from the reactor using the working gas. 1. A method of coating metallic powder particles with silicon comprising:disposing an amount of metallic powder particulates within a fluidizing reactor;removing moisture adsorbed to the powder particles disposed within the reactor using a working gas at a temperature of from about 350° C. to about 450° C. for about 3 to 5 hours;coating the powder particles disposed within the reactor with silicon present within a precursor gas at a temperature of from about 300° C. to about 500° C. for about 0.5 hours to about 6 hours; andpurging the precursor gas from the reactor using the working gas.2. The method of claim 1 , wherein the coating includes coating the powder particles with silicon in an amount such that the coated powder particles have a level of reflectivity that is less than 30% for subsequent processing of the coated powder particles within an additive manufacturing process.3. The method of claim 1 , wherein the working gas comprises argon claim 1 , nitrogen or He.4. The method of claim 2 , wherein the metallic powder particles are aluminum alloy.5. The method of claim 4 , wherein the aluminum alloy comprises at least one of aluminum 5056 claim 4 , aluminum 6061 claim 4 , aluminum 7075 claim 4 , or PANDALLOY aluminum alloy.6. The method of claim 5 , wherein the aluminum alloy comprises aluminum 6061.7. The method of claim 1 , wherein removing moisture adsorbed to the powder particles using a working gas at an elevated temperature for a predetermined time ...

Erosion resistant and hydrophobic article

An erosion resistant and hydrophobic article includes a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions.

EROSION RESISTANT AND HYDROPHOBIC ARTICLE

An erosion resistant and hydrophobic article includes a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions. 1. An article , comprising:a core having a first hardness; anda surface on the core, the surface including a plurality of geometric features having a second, greater hardness and defining a surface porosity by area percent (SP) and a surface solidity by area percent (SS), the surface including a ratio of SS/SP that is 1.8 or greater, the plurality of geometric features and the ratio establishing the surface to be hydrophobic such that the surface would not be hydrophobic in absence of the plurality of geometric features or the ratio, and the second, greater hardness and the ratio establishing an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions such that the erosion rate of the surface would not be equal to or less than an erosion rate of the core in absence of the second, greater hardness or the ratio.2. The article as recited in claim 1 , wherein the plurality of geometric features include a plurality of cylindrical elements.3. The article as recited in claim 1 , wherein each of the plurality of geometric features extends along a respective central axis from a base at the core to a free end claim 1 , each of the plurality of geometric features including a height (h) extending from the base to the free end and a ...

MACHINING OF PARTS HAVING HOLES

Removing of a casting core from a metal casting leaves at least one opening in a surface of the metal. The opening is filled with a sacrificial material. The metal and sacrificial material are machined at the opening. After the machining, a remainder of the sacrificial material is removed. 1. A method comprising:providing a metal casting having a plurality of openings; at least partially immersing in a vessel containing a liquid form of the sacrificial material; and', 'the immersing providing an up-flow of the liquid out of at least one first said opening of the at least one opening responsive to introduction through at least one second said opening of the at least one opening; and, 'filling at least one opening of the plurality of openings with a sacrificial material, the filling comprisingmachining the casting and the sacrificial material at one or more of said first and second openings; andafter the machining, removing a remainder of the sacrificial material.2. The method of wherein:the filling comprises flowing an epoxy through the at least one opening and curing the epoxy to form the sacrificial material.3. The method of wherein:the curing comprises UV curing.4. (canceled)5. The method of wherein:the filling comprises applying at least one support to the casting before the immersing; andduring the immersing, the at least one support supports the casting to provide access for the liquid to pass through said second openings.6. The method of wherein:the immersing is preceded by masking with a non-liquid mask.7. The method of wherein:the masking forms a skirt; andduring the immersing, the skirt allows an exposed portion of the metal casting to lie below a surface level of the liquid.8. The method of wherein:the immersing is sufficient to provide said up-flow of the liquid out of said at least one first said opening within the skirt responsive to introduction through said at least one second said opening.9. The method of wherein:the metal casting forms a blade outer ...

HIGH STRENGTH-TO-DENSITY NANOCELLULAR FOAM

A nanocellular foam has pores, interconnecting ligaments, and nodes where three or more ligaments intersect. The ligament cross section thickness is less than 200 microns and the distance between nodes is less than 1000 microns. A method of fabricating a nanocellular foam comprising forming a compact with one or more powders and applying energy to cause at least one or more powders to undergo a change in state is disclosed. 1. A nanocellular foam comprising pores , interconnecting ligaments , and nodes between the ligaments wherein the ligament cross section thickness or minimum dimension is from about 5 nanometers to about 200 microns and the distance between nodes is from about 15 nanometers to about 1000 microns.2. The nanocellular foam of claim 1 , wherein the ligament cross section thickness or minimum dimension is from about 5 nanometers to about 10 microns and the ligament length is at least three times the cross section thickness.3. The nanocellular foam of claim 1 , wherein the porosity of the foam is from about 5% to about 95%.4. The nanocellular foam of claim 3 , wherein the pore sizes are from about 5 nanometers to about 100 microns.5. The nanocellular foam of claim 4 , wherein the pore sizes are from about 100 nanometers to about 20 microns.6. The nanocellular foam of claim 1 , wherein the foam is a metal claim 1 , intermetallic compound claim 1 , ceramic claim 1 , glass claim 1 , glass ceramic claim 1 , metallic glass claim 1 , or mixtures thereof.7. The nanocellular foam of claim 1 , wherein the foam is a closed or open cell structure claim 1 , or a combination thereof.8. The nanocellular foam of claim 1 , wherein the foam is selected from the group consisting of silicides claim 1 , aluminide intermetallics claim 1 , ternary intermetallics claim 1 , carbides claim 1 , oxides claim 1 , silicates claim 1 , nitrides claim 1 , ternary or multicomponent compounds claim 1 , metallic glasses claim 1 , MAX-phases claim 1 , superalloys claim 1 , and mixtures ...

Hafnon and Zircon Environmental Barrier Coatings for Silicon-Based Components

A method for coating a substrate includes spraying a combination of powders. The combination of powders includes: HfSiO; ZrSiO; and, optionally, at least one of HfOand ZrO. A molar ratio of said HfSiOand HfOcombined to said ZrSiOand ZrOcombined is from 2:1 to 4:1. A molar ratio of said HfSiOto said HfOis at least 1:3. 2. The method of wherein:{'sub': ['0.5', '0.5', '2', '2', '0.5', '0.5', '2', '2'], '#text': 'said molar ratio of said HfSiOand HfOcombined to said ZrSiOand ZrOcombined is from 7:3 to 3:1.'}3. The method of wherein:{'sub': '2', '#text': 'the combination of powders comprises said HfOat a single cation molarity of 0.10 to 0.45.'}4. The method of wherein:{'sub': '2', '#text': 'the combination of powders further comprises said ZrOat a single cation molarity of 0.050 to 0.150.'}5. The method of wherein:{'sub': ['2', '2'], '#text': 'a molar ratio of said HfOto said ZrOis at least 2:1.'}6. The method of wherein:{'sub': ['2', '2'], '#text': 'said molar ratio of said HfOto said ZrOis from 2:1 to 5:1.'}7. The method of wherein:{'sub': ['2', '2', '0.5', '0.5', '2', '0.5', '0.5', '2'], '#text': 'said molar ratio of said HfOto said ZrOis higher than a molar ratio of said HfSiOto said ZrSiO.'}8. The method of wherein:{'sub': ['0.5', '0.5', '2', '0.5', '0.5', '2', '2', '2'], '#text': 'the combination of powders comprises in single cation mol percent at least 95.0% combined said HfSiO, said ZrSiO, and said at least one of HfOand ZrO, if either.'}9. The method of wherein:{'sub': ['1.5', '2'], '#text': 'the combination of powders further comprises CaO, AlO, and SiO.'}10. The method of wherein the spraying is of layer and the method further comprises at least one of:applying a bond coat before the spraying; andapplying a further layer after the spraying.11. The method of including applying the further layer wherein:the further layer is an abradable layer applied by air plasma spray.12. The method of including applying the further layer wherein:the further layer has ...

FIBER-REINFORCED SELF-HEALING BOND COAT

An environmental barrier coating, comprising an environmental barrier coating applied to a substrate containing silicon; the environmental barrier coating comprising an oxide matrix surrounding a fiber-reinforcement structure and a self-healing phase interspersed throughout the oxide matrix. 1. An environmental barrier coating , comprising:an environmental barrier layer applied to a substrate containing silicon; said environmental barrier layer comprising an oxide matrix surrounding a fiber-reinforcement structure and a self-healing phase interspersed throughout said oxide matrix.2. The environmental barrier coating of claim 1 , wherein said substrate comprises a ceramic matrix composite material.3. The environmental barrier coating of claim 1 , wherein said fiber-reinforcement structure comprises a continuous weave of fibers.4. The environmental barrier coating of claim 1 , wherein said fiber-reinforcement structure comprises a SiC material composition.5. The environmental barrier coating of claim 1 , wherein said fiber-reinforcement structure comprises at least one first fiber bundle oriented along a load bearing stress direction of said substrate.6. The environmental barrier coating of claim 5 , wherein said substrate comprises a turbine blade claim 5 , and said load bearing stress direction is oriented along a root to tip direction.7. The environmental barrier coating of claim 5 , wherein said substrate comprises at least one of a turbine vane and a turbine blade claim 5 , and said load bearing stress direction is oriented along the contour of a platform fillet.8. The environmental barrier coating of claim 5 , wherein said fiber-reinforcement structure comprises at least one second fiber bundle oriented orthogonal to said first fiber bundle orientation.9. The environmental barrier coating of claim 8 , wherein said fiber-reinforcement structure comprises at least one third fiber woven between said first fiber bundle and said second fiber bundle.10. The ...

ENVIRONMENTAL BARRIER COATING

An article includes a substrate and a barrier layer on the substrate. The barrier layer includes a matrix, diffusive particles dispersed in the matrix, and gettering particles dispersed in the matrix. The gettering particles include at least one alloyed metal silicide. A composite material and a method of fabricating an article are also disclosed.

PARTICULATES AND METHODS OF MAKING PARTICULATES

A method of making an article using an additive manufacturing technique includes depositing a powder. The powder includes particles formed from an article material and having particle surfaces. A coating formed from a sacrificial coating is deposited over the particle surface. The sacrificial material has a composition that is different from the composition of the article material and is separated from the article material during fusing of the article material into a layer of an additively manufactured article. 1. A method of making an article , comprising: particles comprising an article material and having particle surfaces; and', 'particle coatings comprising a sacrificial material deposited over the particle surfaces, wherein the sacrificial material has a composition different from a composition of the article material;, 'depositing a powder, the powder comprisingseparating the sacrificial material from the article material; andfusing the article material to form a layer of an article.2. The method as recited in claim 1 , wherein separating the sacrificial material comprises:melting the article material; andfloating the sacrificial material in the molten article material or vaporizing the sacrificial material.3. The method as recited in claim 1 , wherein fusing the article material comprises heating the sacrificial material and conducting heat from the sacrificial material into the article material.4. The method as recited in claim 1 , further comprising:depositing additional powder over the separated sacrificial material;separating sacrificial material from the additional powder; andaggregating the sacrificial material underlying the additional powder with the sacrificial material separated from the additional powder.5. The method as recited in claim 4 , wherein the article layer is a first article layer claim 4 , and further comprising fusing the additional article material to form a second article layer claim 4 , wherein fusing the second article layer ...

SURFACE TREATMENT FOR AQUEOUS SLURRY-BASED ENVIRONMENTAL BARRIER COATING

A method for coating a ceramic matrix composite substrate with an environmental barrier coating includes the steps of: treating a surface of a ceramic matrix composite substrate to adjust wettability of the surface; and applying an aqueous slurry-based environmental barrier coating to the surface. The treating step can be a plasma treatment to remove organic contaminants, and can also be a treatment to modify oxidative state of the surface. The treatment can produce a surface for treatment that is hydrophilic and has a contact angle with aqueous-slurry coating materials of less than 40 degrees. 1. A method for coating a ceramic matrix composite substrate with an environmental barrier coating , comprising the steps of:treating a surface of a ceramic matrix composite substrate to adjust wettability of the surface, wherein the treating step is a plasma treating step; andapplying an aqueous slurry-based environmental barrier coating to the surface.2. The method of claim 1 , wherein the substrate is at least one of a turbine vane or a turbine blade.3. The method of claim 1 , wherein the surface has organic contaminants claim 1 , and wherein the treating step removes the organic contaminants.4. The method of claim 3 , wherein the organic contaminants comprise absorbed hydrocarbons claim 3 , surface contaminants from handling claim 3 , machining and packaging claim 3 , and residual contaminants from the manufacturing process.5. The method of claim 1 , wherein the treating step comprises changing the oxidative state of the surface to adjust wettability of the surface.6. (canceled)7. The method of claim 1 , wherein the plasma treating step comprises placing the substrate in a chamber claim 1 , evacuating the chamber claim 1 , introducing process gas to the chamber claim 1 , and generating plasma within the chamber.8. The method of claim 7 , wherein the process gas is selected from the group consisting of fluorine gas claim 7 , Sulphur hexafluoride claim 7 , water vapor claim ...

Chemical and topological surface modification to enhance coating adhesion and compatibility

A process of coating a substrate containing silicon with an environmental barrier coating, comprising altering a surface of the substrate and applying an environmental barrier layer to the surface of the substrate. 1. A process of coating a substrate containing silicon with an environmental barrier coating , comprising:altering a surface of said substrate;exposing said surface to an ultraviolet light; andapplying an environmental barrier layer to said surface of said substrate.2. The process of claim 1 , wherein said substrate comprises a ceramic matrix composite material.3. The process of claim 1 , wherein said altering step comprises at least one of a chemical process and a physical process.4. The process of claim 1 , wherein said surface is exposed to at least one of a plasma claim 1 , a laser claim 1 , ion beam claim 1 , and electron beam.5. The process of claim 1 , wherein said altering step comprises at least one of altering a chemical structure of said surface and altering a chemical function of said surface.6. The process of claim 1 , wherein the surface has organic contaminants claim 1 , and wherein the altering step removes the organic contaminants.7. The process of claim 1 , wherein said substrate comprises at least one of a turbine vane and a turbine blade.8. The process of claim 1 , further comprising:applying a protective layer on said environmental barrier layer.9. The process of claim 1 , wherein said altering step comprises modifying a texture of said surface through at least one of a chemical exposure claim 1 , a physical addition of material claim 1 , a physical removal of material; wherein said texture modification results in a surface topology.10. The process of claim 9 , wherein said surface topology can be created by at least one of embedding particles into said surface claim 9 , directional deposition and mechanical removal of surface material.11. The process of claim 10 , wherein said mechanical removal comprises at least one of creating ...

Self-healing environmental barrier coating

An environmental barrier coating, comprising a substrate containing silicon; an environmental barrier layer applied to the substrate; the environmental barrier layer comprising an oxide matrix; an oxidant getter phase interspersed throughout the oxide matrix; and a self-healing phase interspersed throughout the oxide matrix. 1. An environmental barrier coating , comprising:a substrate containing silicon;an environmental barrier layer applied to said substrate; said environmental barrier layer comprising an oxide matrix;an oxidant getter phase interspersed throughout said oxide matrix; anda self-healing phase interspersed throughout said oxide matrix.2. The environmental barrier coating of claim 1 , wherein said substrate comprises a ceramic matrix composite material.3. The environmental barrier coating of claim 1 , wherein said environmental barrier layer comprises a SiOrich phase.4. The environmental barrier coating of claim 1 , wherein said self-healing phase comprises a glass phase.5. The environmental barrier coating of claim 1 , wherein said oxidant getter phase comprises SiOCwhere 0.5≤x<1; 0≤y<2; 0≤z<2.6. The environmental barrier coating of claim 1 , wherein said self-healing phase comprises a material having properties of being in thermodynamic equilibrium with SiOduring operation at predetermined temperatures.7. The environmental barrier coating of claim 1 , wherein said self-healing phase comprises a material having properties of flowing into cracks formed in said matrix during operation at predetermined temperatures.8. The environmental barrier coating of claim 1 , wherein said self-healing phase comprises a material having properties of flowing into cracks formed in said matrix during operation at predetermined temperatures of from 1800 (982° C.)-3000 degrees Fahrenheit (1650° C.).9. The environmental barrier coating of claim 1 , wherein said substrate comprises at least one of a turbine vane and a turbine blade.10. The environmental barrier coating of ...

EROSION RESISTANT AND HYDROPHOBIC ARTICLE

A gas turbine engine includes an airfoil having a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions. 1. A gas turbine engine comprising:an airfoil having leading and trailing edges, the airfoil including a core having a first hardness and a surface at the leading edge on the core, the surface including a plurality of geometric features having a second, greater hardness and defining a surface porosity by area percent (SP) and a surface solidity by area percent (SS), the surface including a ratio of SS/SP that is 1.8 or greater, the plurality of geometric features and the ratio establishing the surface to be hydrophobic such that the surface would not be hydrophobic in absence of the plurality of geometric features or the ratio, and the second, greater hardness and the ratio establishing an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions such that the erosion rate of the surface would not be equal to or less than an erosion rate of the core in absence of the second, greater hardness or the ratio.2. The gas turbine engine as recited in claim 1 , including a compressor section claim 1 , a combustor in fluid communication with the compressor section and a turbine section in fluid communication with the combustor.3. The gas turbine engine as recited in claim 1 , wherein a remaining surface of the airfoil excludes the ...

COATING FABRICATION METHOD FOR PRODUCING ENGINEERED MICROSTRUCTURE OF SILICATE-RESISTANT BARRIER COATING

A coating fabrication method includes providing engineered granules and thermally consolidating the engineered granules on a substrate to form a silicate-resistant barrier coating. Each of the engineered granules is an aggregate of at least one refractory matrix region and at least one calcium aluminosilicate additive region (CAS additive region) attached with the at least one refractory matrix region. In the thermal consolidation, the refractory matrix region from the engineered granules form grains of a refractory matrix of the silicate-resistant barrier coating and the CAS additive region from the engineered granules form CAS additives that are dispersed in grain boundaries between the grains. 1. A coating fabrication method comprising: at least one refractory matrix region, and', 'at least one calcium aluminosilicate additive region (CAS additive region) attached with the at least one refractory matrix region; and, 'providing engineered granules, wherein each said engineered granule is an aggregate ofthermally consolidating the engineered granules on a substrate to form a silicate-resistant barrier coating, wherein in the thermal consolidation the at least one refractory matrix region from the engineered granules form grains of a refractory matrix of the silicate-resistant barrier coating and the at least one CAS additive region from the engineered granules form CAS additives that are dispersed in grain boundaries between the grains.2. The method as recited in claim 1 , wherein each said engineered granule is a mixed granule that has a plurality of the refractory matrix regions and a plurality of the CAS additive regions attached with the plurality of refractory matrix regions.3. The method as recited in claim 1 , wherein each said engineered granule is a core/shell granule in which the at least one refractory matrix region is a coarse core particle and the at least one CAS additive region is a plurality of fine shell particles attached on the coarse core ...

METHOD FOR CORROSION INHIBITING ADDITIVE

A method of selecting a corrosion-inhibiting substance includes selecting a corrosion-inhibiting substance to include a non-tungstate anodic corrosion inhibitor with respect to an amount of zinc in an aluminum alloy substrate that is to be coated with the corrosion-inhibiting substance. 1. A corrosion resistant article comprising:an aluminum alloy substrate having greater than 5 wt % zinc and 2 wt % or less of copper, the aluminum alloy substrate having a zinc-rich surface; anda layer in contact with the zinc-rich surface of the aluminum substrate, the layer including a non-tungstate anodic corrosion inhibitor and a cathodic corrosion inhibitor, non-tungstate anodic corrosion inhibitor including at least one of a vanadate compound or a molybdate compound and the cathodic corrosion inhibitor including a Group IIIB Periodic Table element.2. The corrosion resistant article as recited in claim 1 , wherein the aluminum alloy substrate includes 5.1-6.1 wt % of the zinc.3. The corrosion resistant article as recited in claim 2 , wherein the aluminum alloy substrate includes about 1.2-2 wt % of the copper.4. The corrosion resistant article as recited in claim 3 , wherein the aluminum substrate comprises manganese claim 3 , magnesium claim 3 , silicon claim 3 , iron claim 3 , chromium claim 3 , and titanium.5. The corrosion resistant article as recited in claim 4 , wherein the aluminum alloy substrate comprises 2.1-2.9 wt % of the magnesium.6. The corrosion resistant article as recited in claim 5 , wherein the aluminum alloy substrate comprises 0.18-0.35 wt % of the chromium.7. The corrosion resistant article as recited in claim 6 , wherein the non-tungstate anodic corrosion inhibitor is zinc molybdate.8. The corrosion resistant article as recited in claim 7 , wherein the cathodic corrosion inhibitor is cerium citrate.9. The corrosion resistant article as recited in claim 1 , wherein the non-tungstate anodic corrosion inhibitor is zinc molybdate.10. The corrosion resistant ...

OXIDATION RESISTANT BOND COAT LAYERS, PROCESSES FOR COATING ARTICLES, AND THEIR COATED ARTICLES

A coated article including an article having a surface; an oxidation resistant bond coat layer deposited on the surface, the oxidation resistant bond coat layer comprising a healing silica matrix and at least one oxygen scavenger forming a metal silicide network dispersed within the healing silica matrix; and a top coat layer disposed upon the oxidation resistant bond coat layer, whereby the oxidation resistant bond coat layer is operable to seal a crack in the top coat layer. 1. A coated article , comprising:an article having a surface;an oxidation resistant bond coat layer deposited on the surface, the oxidation resistant bond coat layer comprising a healing silica matrix and at least one oxygen scavenger forming a metallic, intermetallic, or metal silicide network dispersed within the healing silica matrix; andan environmental protective top coat layer disposed upon the oxidation resistant bond coat layer, whereby the oxidation resistant bond coat layer is operable to repair a crack in the top coat layer.2. The coated article as recited in claim 1 , wherein the metallic claim 1 , intermetallic claim 1 , or metal silicide network is embedded in the silicon oxide based healing silica matrix claim 1 , the healing silica matrix contains glass phases having a viscosity of 10poise to 10poise at a temperature of 1 claim 1 ,292 F (700 C) to 3 claim 1 ,272 F (1 claim 1 ,800 C) to flow into the cracks.3. The coated article as recited in claim 1 , wherein the metallic claim 1 , intermetallic claim 1 , or metal silicide network comprises 30-90% by volume of the oxidation resistant bond coat layer.4. The coated article as recited in claim 1 , wherein interstices in the metallic claim 1 , intermetallic claim 1 , or metal silicide network is at least partially filled with the silica based healing matrix to protect the surface and provide the healing function.5. The coated article as recited in claim 1 , wherein the metallic claim 1 , intermetallic claim 1 , or metal silicide ...

Method for corrosion inhibiting additive

A method of selecting a corrosion-inhibiting substance includes selecting a corrosion-inhibiting substance to include a non-tungstate anodic corrosion inhibitor with respect to an amount of zinc in an aluminum alloy substrate that is to be coated with the corrosion-inhibiting substance.

METHOD AND SYSTEM FOR MOLDED COATING ON CMC

A method of forming a coating includes providing a mold that has a flexible wall that defines a mold cavity, inserting a component that is to be coated into the mold cavity, the component having a component surface roughness and there being a coating gap defined between the component and the flexible wall of the mold cavity, introducing a molding slurry into the mold cavity, the molding slurry filling the coating gap and contacting the component so as to overcoat the component surface roughness, solidifying the molding slurry to form a green coating on the component, and consolidating the green coating to form a final coating on the component, the final coating having a coating surface roughness that is less than the component surface roughness. 1. A method of forming a coating , comprising:providing a mold that has a flexible wall that defines a mold cavity;inserting a component that is to be coated into the mold cavity, the component having a component surface roughness and there being a coating gap defined between the component and the flexible wall of the mold cavity;introducing a molding slurry into the mold cavity, the molding slurry filling the coating gap and contacting the component so as to overcoat the component surface roughness;solidifying the molding slurry to form a green coating on the component; andconsolidating the green coating to form a final coating on the component, the final coating having a coating surface roughness that is less than the component surface roughness.2. The method as recited in claim 1 , wherein the inserting includes situating the component in the mold cavity such that the coating gap is of uniform thickness.3. The method as recited in claim 1 , wherein the inserting includes using one or more bumpers in the mold cavity to space the component from the flexible wall.4. The method as recited in claim 3 , wherein the component has one or more cooling holes claim 3 , and the one or more bumpers plug the one or more cooling holes.5 ...

ACCELERATED CVI DENSIFICATION OF CMC THROUGH INFILTRATION

A process for densification of a ceramic matrix composite comprises forming a reinforcing ceramic continuous fiber stack having a central zone bounded by an outer zone adjacent; locating first particles within the central zone; coating the first particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; locating second particles within the outer zone; coating the second particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; forming the stack into a predetermined three dimensional shape; and densifying the stack. 1. A process for densification of a ceramic matrix composite comprising:forming a reinforcing ceramic continuous fiber stack having a central zone bounded by a middle zone and an outer zone adjacent said middle zone opposite said central zone;locating small particles within said central zone;coating said small particles and said ceramic fibers with silicon carbide through chemical vapor infiltration;locating medium particles within said middle zone;coating said medium particles and said ceramic fibers with silicon carbide through chemical vapor infiltration;locating large particles within said outer zone; and coating said large particles and said ceramic fibers with silicon carbide through chemical vapor infiltration;forming said preform into a predetermined three dimensional shape; anddensifying said stack.2. The process of claim 1 , wherein said reinforcing ceramic continuous fiber stack comprises fiber tows aligned into a plies claim 1 , each fiber tow having a surface having pores.3. The process of claim 2 , wherein said step of locating small particles within said central zone further comprises coating said surface of the fiber tow proximate said central zone with a slurry containing said small particles.4. The process of claim 2 , wherein said step of locating medium particles within said middle zone further comprises coating said surface of the fiber tow proximate said middle zone ...

ENVIRONMENTAL BARRIER COATING

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix of SiO2 and a dispersion of silicon oxycarbide particles in the matrix. The silicon oxycarbide particles have Si, O, and C in a covalently bonded network, and a dispersion of barium-magnesium alumino-silicate particles in the matrix. The barium-magnesium alumino-silicate particles have an average maximum dimension that is between about 10-40% of an average maximum dimension of the silicon oxycarbide particles. A composite material and a method of applying a barrier layer to a substrate are also disclosed. 1. An article comprising:a ceramic-based substrate; and{'sub': '2', 'a barrier layer on the ceramic-based substrate, the barrier layer including a matrix of SiO, a dispersion of silicon oxycarbide particles in the matrix, the silicon oxycarbide particles having Si, O, and C in a covalently bonded network, and a dispersion of barium-magnesium alumino-silicate particles in the matrix, the barium-magnesium alumino-silicate particles having an average maximum dimension that is between about 10-40% of an average maximum dimension of the silicon oxycarbide particles.'}2. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 1-30% of the barium-magnesium alumino-silicate particles.3. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 30-94% of the silicon oxycarbide particles.4. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 5-40% of the matrix of SiO.5. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 1-30% of the barium-magnesium alumino-silicate particles claim 1 , 5-40% of the matrix of SiO claim 1 , and a balance of the silicon oxycarbide particles.6. The article as recited in claim 5 , wherein the barrier layer includes claim 5 , by ...

ENVIRONMENTAL BARRIER COATING WITH POROUS BOND COAT LAYER

A gas turbine engine article includes a substrate and an environmental barrier coating (EBC) system disposed on the substrate. The EBC system includes, from the substrate, a dense bond coat layer, a porous bond coat layer, and a topcoat layer in contact with the porous bond coat layer at an interface. The porous bond coat layer includes a matrix, oxygen-scavenging gas-evolution particles dispersed through the matrix, and engineered buffer pores. The oxygen-scavenging gas-evolution particles react with oxygen and generate a gaseous byproduct that diffuses through the interface to escape the EBC system. The engineered buffer pores buffer diffusion of gaseous byproduct to the interface by retaining at least a portion of the gaseous byproduct. 1. A gas turbine engine article comprising:a substrate; andan environmental barrier coating (EBC) system disposed on the substrate, the EBC system including, from the substrate, a dense bond coat layer, a porous bond coat layer, and a topcoat layer in contact with the porous bond coat layer at an interface, the porous bond coat layer including a matrix, oxygen-scavenging gas-evolution particles dispersed through the matrix, and engineered buffer pores, the oxygen-scavenging gas-evolution particles reacting with oxygen and generating a gaseous byproduct that diffuses through the interface to escape the EBC system, and the engineered buffer pores buffering diffusion of gaseous byproduct to the interface by retaining at least a portion of the gaseous byproduct.2. The gas turbine engine article as recited in claim 1 , wherein the oxygen-scavenging gas-evolution particles are selected from the group consisting of silicon oxycarbide particles claim 1 , silicon carbide particles claim 1 , and combinations thereof.3. The gas turbine engine article as recited in claim 1 , wherein the matrix comprises silica.4. The gas turbine engine article as recited in claim 1 , wherein the topcoat layer is selected from the group consisting of oxides ...

FABRICATION OF ARTICLES FROM NANOWIRES

A method of fabricating an article includes providing an arrangement of loose nanowires and bonding the loose nanowires together into a unitary cellular structure. 1. A method of fabricating an article , the method comprising:providing an arrangement of loose nanowires; andbonding the nanowires together into a unitary cellular structure.2. The method as recited in claim 1 , including claim 1 , prior to the bonding claim 1 , forming the loose nanowires into a geometry of an end-use article.3. The method as recited in claim 2 , wherein the forming of the loose nanowires into the geometry of the end-use article includes depositing successive layers of the nanowires.4. The method as recited in claim 2 , wherein the forming of the loose nanowires into the geometry includes depositing the loose nanowires into a mold.5. The method as recited in claim 1 , wherein at least a portion of the nanowires are nickel or a nickel alloy.6. The method as recited in claim 1 , wherein the arrangement of loose nanowires includes nanowires of differing compositions.7. The method as recited in claim 1 , wherein at least a portion of the nanowires are a substantially pure metal.8. The method as recited in claim 1 , wherein at least a portion of the nanowires are a ceramic material.9. The method as recited in claim 1 , wherein the bonding includes thermal sintering or diffusion.10. The method as recited in claim 1 , wherein the providing of the arrangement of loose nanowires includes forming metallic nanowires by wet chemical synthesis and then drying the metallic nanowires claim 1 , to directly produce the metallic nanowires without reduction of an oxide of the metal of the metallic nanowires.11. The method as recited in claim 1 , wherein the unitary cellular structure includes open cells claim 1 , with a majority of the open cells having a maximum size of less than ten micrometers.12. The method as recited in claim 1 , including claim 1 , before the bonding claim 1 , consolidating the ...

Method for synthesizing nanowires and nanofoam

A method for making a plurality of metallic nanowires includes combining a metallic precursor with a solvent to form a metallic precursor solution. A quantity of oxalic acid is added to the metallic precursor solution to form a reduction solution. A plurality of nanowires are precipitated out from the reduction solution.

SELF-HEALING MATRIX FOR A CERAMIC COMPOSITE

A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region. 1. A method for forming a self-healing ceramic matrix composite (CMC) component , the method comprising:depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component; anddepositing a second self-healing particulate material in a second region of the CMC preform, wherein the first and second regions are non-overlapping and wherein the second self-healing particulate material is absent from the first region;wherein the first and second self-healing particulate materials have different chemical compositions.2. The method of claim 1 , wherein the first self-healing particulate material is selected from a group consisting of silicon boride claim 1 , boron carbide claim 1 , silicon borocarbide claim 1 , silicon boronitrocarbide claim 1 , aluminum nitride and mixtures thereof claim 1 , and wherein the second self-healing particulate material is selected from a group consisting of borides of rare earth elements claim 1 , hafnium boride claim 1 , zirconium boride claim 1 , titanium boride claim 1 , tantalum boride claim 1 , silicides of rare earth elements claim 1 , hafnium silicide claim 1 , zirconium silicide claim 1 , titanium silicide claim 1 , tantalum silicide claim 1 , molybdenum disilicide claim 1 , aluminum oxide claim 1 , alkaline metal oxides claim 1 , oxide of rare earth elements claim 1 , hafnium oxide and zirconium oxide and mixtures thereof.3. The method of claim 2 , wherein the first region comprises an inner core of the CMC preform claim 2 , and wherein the second region comprises an outer region of the CMC ...

ENVIRONMENTAL BARRIER COATING

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and a network of gettering particles in the matrix phase. The gettering particles have an average maximum dimension between about 30 and 70 microns. The gettering particles have maximum dimensions that range from about 1 to 100 microns, and a dispersion of barium-magnesium alumino-silicate particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed. 1. An article comprising:a ceramic-based substrate; and a matrix phase,', 'a network of gettering particles in the matrix phase, wherein the gettering particles have an average maximum dimension between about 30 and 70 microns, wherein the gettering particles have maximum dimensions that range from about 1 to 100 microns, and', 'a dispersion of diffusive particles in the matrix phase., 'a barrier layer on the ceramic-based substrate, the barrier layer including2. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 30-94% of the gettering particles.3. The article as recited in claim 2 , wherein the barrier layer includes claim 2 , by volume claim 2 , 60-90% of the gettering particles.4. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 1-30% of the diffusive particles claim 1 , 5-40% of the matrix of SiO claim 1 , and a balance of the gettering particles.5. The article as recited in claim 1 , wherein the diffusive particles have an average maximum dimension that is smaller than the average maximum dimension of the gettering particles.6. The article as recited in claim 1 , wherein the gettering particles have an average maximum dimension that is between about 40 and 60 microns.7. The article as recited in claim 6 , wherein the gettering particles have dimensions between about 5-75 microns.8. The article as recited in ...

ENVIRONMENTAL BARRIER COATING

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and gettering particles in the matrix phase. The gettering particles with an aspect ratio greater than one are aligned such that a maximum dimension of the gettering particles extends along an axis that is generally parallel to the substrate. The barrier layer includes a dispersion of diffusive particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed. 1. An article comprising:a ceramic-based substrate; and a matrix phase,', 'gettering particles in the matrix phase, wherein at least some of the gettering particles have an aspect ratio greater than one, and wherein the gettering particles with an aspect ratio greater than one are aligned such that a maximum dimension of the gettering particles extends along an axis that is generally parallel to the substrate, and, 'a barrier layer on the ceramic-based substrate, the barrier layer includinga dispersion of diffusive particles in the matrix phase.2. The article as recited in claim 1 , wherein the diffusive particles include at least one of barium-magnesium alumino-silicate particles claim 1 , barium strontium aluminum silicate particles claim 1 , magnesium silicate particles claim 1 , alkaline earth aluminum silicate particles claim 1 , yttrium aluminum silicate particles claim 1 , ytterbium aluminum silicate particles claim 1 , and rare earth metal aluminum silicate particles.3. The article as recited in claim 1 , wherein the gettering particles include at least one of silicon oxycarbide (SiOC) particles claim 1 , silicon carbide (SiC) particles claim 1 , silicon nitride (SiN) particles claim 1 , silicon oxycarbonitride (SiOCN) particles claim 1 , silicon aluminum oxynitride (SiAlON) particles claim 1 , and silicon boron oxycarbonitride (SiBOCN) particles.4. The article as recited in claim 3 , wherein the ...

ELECTRIC COMPONENT INCLUDING CUSTOM METAL GRAIN ORIENTATION

An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux. 1. A method of fabricating an electric device , the method comprising:determining flux paths of a soft magnetically-conductive material of the electric device;determining expected amplitudes of the flux paths and comparing the expected amplitudes to an amplitude threshold; andselectively forming grain oriented metal portions in the soft magnetically-conductive material, the grain oriented metal portions formed at low amplitude locations where the expected flux amplitude is at or below the amplitude threshold.2. The method of claim 1 , wherein forming the grain oriented metal portions includes forming metal grains having an orientation that is parallel to the flux paths at the low amplitude locations.3. The method of claim 2 , wherein the grain oriented metal portions are formed in at least one of a stator and a rotor of an electrical motor.4. The method of claim 3 , wherein the grain oriented metal portions of the stator are formed in the stator teeth and an outer yoke portion.5. The method of claim 2 , wherein the grain oriented metal portions are formed in at least one of a vertical strap and a horizontal strap of an electrical transformer. This application is a divisional of U.S. application Ser. No. 15/349,643, filed on Nov. 11, 2016, which claims the benefit of U.S. Provisional Application No. 62/254,364, filed on Nov. 12, 2015, both applications being incorporated herein by reference in their entirety.This invention was made with government support under DE-AR0000308 awarded by the U.S. Department of Energy. The government has certain rights in the ...

SELF-HEALING MATRIX FOR A CERAMIC COMPOSITE

A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region. 1. A ceramic matrix composite (CMC) component comprising:a plurality of fibers; and a first region comprising deposits of a first self-healing material capable of sealing cracks in the matrix; and', 'a second region distinct from the first region and comprising deposits of a second self-healing material capable of regenerating an environmental barrier coating;', 'wherein the deposits of the first and second self-healing materials are dispersed throughout the matrix in each of the first and second regions., 'a ceramic matrix, wherein the plurality of fibers are embedded in the ceramic matrix and wherein the ceramic matrix comprises2. The CMC component of claim 1 , wherein the first self-healing material is selected from a group consisting of silicon boride claim 1 , boron carbide claim 1 , silicon borocarbide claim 1 , silicon boronitrocarbide claim 1 , and mixtures thereof claim 1 , and wherein the second self-healing material is selected from a group consisting of borides of rare earth elements claim 1 , hafnium boride claim 1 , zirconium boride claim 1 , titanium boride claim 1 , tantalum boride claim 1 , silicides of rare earth elements claim 1 , hafnium silicide claim 1 , zirconium silicide claim 1 , titanium silicide claim 1 , tantalum silicide claim 1 , molybdenum disilicide claim 1 , aluminum oxide claim 1 , alkaline metal oxides claim 1 , oxide of rare earth elements and mixtures thereof.3. The CMC component of claim 1 , wherein the first region comprises an inner core of the CMC component and wherein the second region comprises an outer region of the ...

ENVIRONMENTAL BARRIER COATING AND METHOD OF APPLYING AN ENVIRONMENTAL BARRIER COATING

A method of fabricating a barrier layer on a substrate includes mixing gettering particles, diffusive particles, and matrix material in a carrier fluid to form a slurry; applying a layer of the slurry to the substrate; adjusting the surface of the layer of the slurry; and sintering the layer of the slurry to form a barrier layer. An article is also disclosed. 1. A method of fabricating a barrier layer on a substrate , comprising:mixing gettering particles, diffusive particles, and matrix material in a carrier fluid to form a slurry;applying a layer of the slurry to a substrate;adjusting the surface of the layer of the slurry; andsintering the layer of the slurry to form a barrier layer.2. The method of claim 1 , further comprising partially curing the layer of the slurry prior to the smoothing step.3. The method of claim 1 , wherein the adjusting is achieved by applying force to the layer of the slurry.4. The method of claim 3 , wherein the force is applied by a mold.5. The method of claim 4 , wherein the adjusting includes placing the substrate with the layer of the slurry into a first tool of a mold after the applying step and applying force to the layer of the slurry by pressing a second tool onto the layer of the slurry.6. The method of claim 4 , further comprising placing the substrate into a mold claim 4 , and wherein the adjusting and applying are performed simultaneously by injecting the slurry into the mold.7. The method of claim 4 , wherein the layer of the slurry is heated during the adjusting.8. The method of claim 4 , further comprising partially curing the layer of the slurry prior to the adjusting step.9. The method of claim 4 , wherein the sintering is performed in the mold.10. The method of claim 1 , wherein the adjusting includes smoothing the surface of the layer of the slurry.11. The method of claim 10 , wherein the smoothing reduces the macro-level surface roughness of the layer of the slurry by at least 50%.12. The method of claim 1 , wherein ...

POWDER METAL WITH ATTACHED CERAMIC NANOPARTICLES

A powder material includes spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles. 1. A powder material comprising:spherical metal particles; anda spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles.2. The powder material as recited in claim 1 , wherein the spherical metal particles are selected from the group consisting of nickel claim 1 , chromium claim 1 , and combinations thereof.3. The powder material as recited in claim 1 , wherein the ceramic nanoparticles are selected from the group consisting of oxides claim 1 , nitrides claim 1 , carbides claim 1 , and combinations thereof claim 1 , and the powder material has a composition claim 1 , by weight claim 1 , of 0.1-5% of the ceramic nanoparticles.4. The powder material as recited in claim 1 , wherein the ceramic nanoparticles are oxide nanoparticles.5. The powder material as recited in claim 1 , wherein the ceramic nanoparticles are zirconium oxide nanoparticles.6. The powder material as recited in claim 1 , wherein the spherical metal particles are nickel-based particles and include chromium.7. The powder material as recited in claim 6 , wherein the ceramic nanoparticles are zirconium oxide nanoparticles.8. The powder material as recited in claim 7 , wherein the powder material has a composition claim 7 , by weight claim 7 , of 0.1-5% of the ceramic nanoparticles. This application is a divisional of U.S. patent application Ser. No. 15/678,260 filed Aug. 16, 2017, which is a continuation of U.S. patent application Ser. No. 14/670,623 filed Mar. 27, 2015.This invention was made with government support under contract number W911NF-14-2-0011 awarded by the United States Army. The government has certain rights in the invention.High performance alloys can be used in relatively severe environments to provide enhanced mechanical properties, such as high strength, creep resistance, and oxidation resistance. ...

FRICTION BRAKE ASSEMBLY WITH AN ABRADABLE METAL FOAM BRAKE PAD

A brake assembly and a method for manufacturing a brake assembly are provided. The brake assembly includes a brake pad affixed to a substrate. The brake pad extends from the substrate to a brake pad friction surface, and includes abradable cellular metal foam with the hardened ceramic particles. 1. A brake assembly , comprising:a substrate; anda brake pad comprising abradable cellular metal foam, wherein the brake pad is affixed to the substrate, and extends away from the substrate to form a brake pad friction surface.2. The brake assembly of claim 1 , wherein the metal foam comprises open-cell metal foam.3. The brake assembly of claim 1 , wherein the metal foam comprises closed-cell metal foam.4. The brake assembly of claim 1 , wherein the metal foam comprises a lattice structure.5. The brake assembly of claim 1 , wherein the metal foam has a metal foam pore to metal foam material volumetric porosity of greater than about one to nineteen.6. The brake assembly of claim 5 , wherein the volumetric porosity is between about three to seventeen and about three to about seven.7. The brake assembly of claim 1 , wherein the metal foam has a metal foam pore size that is one of less than and equal to about one hundred fifty microns.8. The brake assembly of claim 1 , wherein the friction surface has a coefficient of friction greater than about 0.3.9. The brake assembly of claim 1 , wherein the metal foam is operable to withstand a temperature greater than about eight hundred degrees Centigrade claim 1 , and a compressive load greater than forty mega Pascals.10. The brake assembly of claim 1 , wherein the metal foam includes at least one of tungsten claim 1 , chromium claim 1 , cobalt claim 1 , nickel claim 1 , titanium claim 1 , silicon claim 1 , molybdenum claim 1 , carbon claim 1 , boron and aluminum.11. The brake assembly of claim 1 , wherein the substrate includes one of steel and iron.12. The brake assembly of claim 1 , further comprising a bond layer disposed between the ...

METHOD OF COATING METALLIC POWDER PARTICLES

A method and system for coating metallic powder particles is provided. The method includes: disposing an amount of metallic powder particulates within a fluidizing reactor; removing moisture adhered to the powder particles disposed within the reactor using a working gas; coating the powder particles disposed within the reactor using a precursor gas; and purging the precursor gas from the reactor using the working gas. 1. A method comprising:disposing an amount of metallic powder particulates within a fluidizing reactor; andcoating the metallic powder particulates disposed within the reactor with a material present within a precursor gas;wherein the coating includes coating the metallic powder particulates with the material in an amount such that the coated metallic powder particulates have a level of reflectivity that is acceptable for subsequent processing of the coated metallic powder particulates within an additive manufacturing process.2. The method of claim 1 , further comprising:removing moisture adhered to the metallic powder particulates disposed within the reactor using a working gas.3. The method of claim 2 , wherein the coating occurs subsequent to said removing of moisture.4. The method of claim 2 , further comprising:purging the precursor gas from the reactor using the working gas.5. The method of claim 1 , further comprising:purging the precursor gas from the reactor using a working gas.6. The method of claim 1 , wherein the metallic powder particulates are aluminum alloy.7. The method of claim 6 , wherein the aluminum alloy is selected from the group consisting of aluminum 5056 claim 6 , aluminum 6061 claim 6 , or aluminum 7075.8. The method of claim 1 , wherein the precursor gas comprises silicon.9. The method of claim 8 , wherein the precursor gas is selected from the group consisting of silane (SiH) claim 8 , disilane (SiH) claim 8 , chlorosilane (HClSi) claim 8 , or dichlorosilane (SiHCl).10. The method of claim 2 , wherein the removing moisture ...

TRANSPIRATION-COOLED ARTICLE HAVING NANOCELLULAR FOAM

A transpiration-cooled article includes a body wall that has first and second opposed surfaces. The first surface is adjacent a passage that is configured to receive a pressurized cooling fluid. At least a portion of the body wall includes a nanocellular foam through which the pressurized cooling fluid from the passage can flow to the second surface. The article can be an airfoil that includes an airfoil body that has an internal passage and an outer gas-path surface. At least a portion of the airfoil body includes a nanocellular foam through which cooling fluid from the internal passage can flow to the gas-path surface. 1. A transpiration-cooled airfoil comprising:an airfoil body that includes an internal passage and an outer gas-path surface, andat least a portion of the airfoil body includes a nanocellular foam through which cooling fluid from the internal passage can flow to the gas-path surface.2. The transpiration-cooled article as recited in claim 1 , wherein the airfoil body includes at least one discrete window of the nanocellular foam surrounded by solid walls.3. The transpiration-cooled article as recited in claim 1 , wherein the nanocellular foam has an average pore size of 10 micrometers to 100 nanometers.4. The transpiration-cooled article as recited in claim 1 , wherein the nanocellular foam has a porosity of 5-95%.5. The transpiration-cooled article as recited in claim 4 , wherein the nanocellular foam has a pore volume of 0.01-0.1 milliliters per gram.6. The transpiration-cooled airfoil as recited in claim 1 , wherein the airfoil body includes a leading edge and a trailing edge and a first sidewall and a second sidewall that is spaced apart from the first sidewall claim 1 , the first sidewall and the second sidewall join the leading edge and the trailing edge and at least partially define the internal passage claim 1 , and the nanocellular foam is located in the first sidewall claim 1 , and the first sidewall is a suction side of the airfoil body.7. ...

SOLID OXIDE FUEL SYSTEM

A system and method satisfies temperature and pressure requirements of solid oxide fuel cell system in a manner that increases the overall efficiency and decreases the overall weight of system. The system and method include a secondary blower for boosting air stream pressure level sufficient for operation of a reformer that is designed to minimize pressure drop; an integrated heat exchanger for recovering heat from exhaust and comprising multiple flow fields for ensuring inlet temperature requirements of a solid oxide fuel cell are met; and a thermal enclosure for separating hot zone components from cool zone components for increasing thermal efficiency of the system and better thermal management. 1. A system comprising:a solid oxide fuel cell having a cathode flow field, an anode flow field, and an exhaust flow field, the cathode flow field and the anode flow field configured to direct exhaust from the cathode flow field and the anode flow field to the exhaust flow field;a heat exchanger having a cathode heat exchanger flow field, an anode heat exchanger flow field, and a portion of the exhaust flow field;a fuel reformer configured to generate a reformate stream;a first blower configured to receive air from an air source and generate a first fluid stream at a first pressure level, wherein a first portion of the first fluid stream is directed to the cathode heat exchanger flow field and the cathode flow field; anda second blower configured to receive a second portion of the first fluid stream and generate a second fluid stream at a second pressure level that is greater than the first pressure level, wherein a first portion of the second fluid stream is directed to the fuel reformer to generate the reformate stream, the reformate stream having at least a portion that is directed from the fuel reformer to the anode flow field.2. The system of claim 1 , wherein the first pressure level is sufficient to overcome a pressure drop across the cathode heat exchanger flow ...

METHOD OF COATING AN IRON-BASED ARTICLE

A method of coating an iron-based article includes a first heating step of heating a substrate that includes an iron-based material in the presence of an aluminum source material and halide diffusion activator. The heating is conducted in a substantially non-oxidizing environment, to cause the formation of an aluminum-rich layer in the iron-based material. In a second heating step, the substrate that has the aluminum-rich layer is heated in an oxidizing environment to oxidize the aluminum in the aluminum-rich layer. 1. A method of coating an iron-based article , the method comprising:in a first heating step, heating a substrate including an iron-based material in the presence of an aluminum source material and a halide diffusion activator, in a substantially non-oxidizing environment, to cause the formation of an aluminum-rich layer on at least a portion of the iron-based material; andin a second heating step, heating the substrate that has the aluminum-rich layer in an oxidizing environment to oxidize the aluminum in the aluminum-rich layer.2. The method as recited in claim 1 , wherein the first heating step includes heating at a heating temperature such that a ratio of the melting temperature of the iron-based material to the heating temperature is 1.5-2.1.3. The method as recited in claim 1 , wherein the first heating step includes heating at a heating temperature such that a ratio of the melting temperature of the iron-based material to the heating temperature is 1.6-1.9.4. The method as recited in claim 1 , wherein the second heating step is conducted at a heating temperature of 800°-1000° C.5. The method as recited in claim 1 , further comprising claim 1 , after the second heating step claim 1 , cooling the substrate that has the alumina at a cooling rate that is equal to or less than 10° C. per minute.6. The method as recited in claim 1 , further comprising claim 1 , after the second heating step claim 1 , cooling the substrate that has the alumina at a ...

Anodic-Cathodic Corrosion Inhibitor-Conductive Polymer Composite

A conductive polymer corrosion protective composite is provided which may be used as a coating for imparting corrosion protection to structures such as turbine engine components. The composite comprises an organic-inorganic component and corrosion inhibitive pigments comprising an anodic corrosion inhibitor and a cathodic corrosion inhibitor. The anodic corrosion inhibitor may be selected from the group consisting of compounds of vanadium, molybdenum, tungsten, and mixtures thereof. The cathodic corrosion inhibitor may be selected from the group consisting of cerium, neodymium, praseodymium, and mixtures thereof. 113-. (canceled)14. A method for providing corrosion protection to a substrate comprising the steps of:providing a substrate; andforming a conductive polymer corrosion protective composite comprising an organic-inorganic component and a corrosion inhibitive additive comprising an anodic corrosion inhibitor and a cathodic corrosion inhibitor; andapplying said conductive polymer corrosion protective composite to at least one surface of said substrate.15. The method according to claim 14 , wherein said substrate providing step comprises providing a turbine engine component.16. The method according to claim 14 , wherein said conductive polymer corrosion protective composite forming step comprises dissolving the anodic corrosion inhibitor and the cathodic corrosion inhibitor in a carrier containing said organic-inorganic component.17. The method according to claim 16 , wherein said anodic corrosion inhibitor and cathodic corrosion inhibitor dissolving step comprises dissolving enough of said anodic corrosion and cathodic corrosion inhibitors in said carrier so that there is a concentration of the anodic corrosion inhibitor and the cathode corrosion inhibitor in the range of from 5 to 250 grams/liter and a metal complexing agent is present in a concentration of from 2 to 250 grams/liter.18. The method according to claim 16 , wherein said anodic corrosion ...

Tube structures for heat exchanger

A heat exchanger includes a plurality of fins and a plurality of tubes passing a fluid therethrough, extending through the plurality of fins and radially expanded into an interference fit therewith. At least one tube of the plurality of tubes includes an outer diameter, an inner diameter, and a plurality of ridges extending from the inner diameter inwardly into an interior of the tube. A tube internal surface area per unit of length of the tube multiplied by the ratio of the outer diameter and tube wall thickness is equal to or greater than about 30.0.

POWDER METAL WITH ATTACHED CERAMIC NANOPARTICLES

A method for processing a powder material includes feeding a powder material through an additive processing machine to deposit multiple layers of the powder material onto one another and using an energy beam to thermally fuse selected portions of the layers to one another with reference to data relating to a particular cross-section of an article being formed. The powder material has spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles. The ceramic nanoparticles form a dispersion of reinforcement through the formed article. 1. A method for processing a powder material , the method comprising:feeding a powder material through an additive processing machine to deposit multiple layers of the powder material onto one another, the powder material having spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles; andusing an energy beam to thermally fuse selected portions of the layers to one another with reference to data relating to a particular cross-section of an article being formed, the ceramic nanoparticles forming a dispersion of reinforcement through the formed article.2. The method as recited in claim 1 , wherein the ceramic nanoparticles are selected from the group consisting of oxides claim 1 , nitrides claim 1 , carbides claim 1 , and combinations thereof.3. The method as recited in claim 1 , wherein the ceramic nanoparticles are oxide nanoparticles.4. The method as recited in claim 1 , wherein the ceramic nanoparticles are zirconium oxide nanoparticles.5. The method as recited in claim 1 , wherein the powder material has a composition claim 1 , by weight claim 1 , of 0.1-5% of the ceramic nanoparticles.6. The method as recited in claim 1 , wherein the spherical metal particles are selected from the group consisting of nickel claim 1 , chromium claim 1 , aluminum claim 1 , titanium claim 1 , iron claim 1 , and combinations ...

STRUCTURED POWDER PARTICLES FOR FEEDSTOCK IMPROVEMENT FOR LASER BASED ADDITIVE MANUFACTURING

A process comprising providing a metallic first powder having a plurality of first particles. The process includes adding a second material to the first powder, the second material having a plurality of second particles. The process includes combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition. 1. A process comprising:providing a metallic first powder having a plurality of first particles;adding a second material to the first powder, the second material having a plurality of second particles;combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.2. The process according to claim 1 , wherein said outer surface portion includes properties selected from the group consisting of low flammability claim 1 , low reflectivity claim 1 , low melting point and low moisture/contamination pick up.3. The process according to wherein said low reflectivity outer surface portion is selected from the group consisting of Mg claim 2 , W claim 2 , Fe claim 2 , Mo claim 2 , Cr claim 2 , and Si.4. The process according to wherein said low flammability outer surface portion is selected from the group consisting of Zr claim 2 , Ti claim 2 , Si claim 2 , Cr claim 2 , Mn claim 2 , Sn claim 2 , Zn claim 2 , Pb claim 2 , Mo claim 2 , Co claim 2 , W claim 2 , Cu claim 2 , and Ni.5. The process according to claim 1 , wherein said outer surface portion comprises a continuous coating.6. The process according to claim 1 , wherein said outer surface portion comprises a discontinuous coating.7. The process according to claim 1 , further comprising:forming an additional layer ...

HEAT TRANSFER SYSTEM WITH COATED FLUID CONDUIT

A heat transfer system having a heat transfer fluid circulation loop of a first fluid is disclosed. A conduit is disposed in the fluid circulation loop with an inner surface in contact with the first fluid at a first pressure. An outer surface of the first conduit is in contact with a second fluid at a second pressure that is 69 kPa to 13771 kPa (10 psi to 2000 psi) higher than the first pressure. The conduit also includes a polyurea coating on its outer surface. 1. A heat transfer system comprising a circulation loop of a first fluid , comprising a conduit disposed in said circulation loop , the conduit having an inner surface in contact with the first fluid at a first pressure and an outer surface in contact with a second fluid at a second pressure , wherein the first pressure is higher than the second pressure by 69 kPa to 13771 kPa (10 psi to 2000 psi) , and wherein the conduit includes a coating on the second surface comprising a polyurea.2. The heat transfer system of claim 1 , wherein the polyurea coating has a thickness of 100-2600 μm.3. The heat transfer system of claim 1 , wherein the polyurea coating has a thickness of 250-1000 μm.4. The heat transfer system of claim 1 , wherein the polyurea coating has a thickness of 760-2540 μm.5. The heat transfer system of claim 1 , wherein the polyurea coating has a tensile strength of at least 1.52 MPa (2200 psi) claim 1 , as determined according to ASTM D638-10.6. The heat transfer system of claim 5 , wherein the polyurea coating has a tensile strength of 1.52-1.72 MPa (2200-2500 psi) claim 5 , as determined according to ASTMD638-10.7. The heat transfer system of claim 1 , wherein the polyurea coating has an elongation of 300-350% claim 1 , as determined according to ASTM D638-10.8. The heat transfer system of claim 1 , wherein the polyurea coating has an adhesion to the conduit's outer surface of 800 to 1000 psi claim 1 , as determined according to ASTM D4541.9. The heat transfer system of claim 1 , wherein the ...

ENVIRONMENTAL BARRIER COATING

An environmental barrier coating includes a barrier layer which includes a matrix, diffusive particles, and gettering particles; and a calcium-magnesia alumina-silicate (CMAS)-resistant component. The CMAS-resistant component includes hafnium silicate and a rare earth hafnate. An article and a method of fabricating an article are also disclosed. 1. An environmental barrier coating , comprising:a barrier layer, the barrier layer including a matrix, diffusive particles, and gettering particles; anda calcium-magnesia alumina-silicate (CMAS)-resistant component, wherein the CMAS-resistant component includes hafnium silicate and a rare earth hafnate.2. The environmental barrier coating of claim 1 , wherein the rare earth hafnate is La-hafnate claim 1 , Nd-hafnate or Pr-hafnate.3. The environmental barrier coating of claim 1 , wherein the CMAS-resistant layer includes a glass component.4. The environmental barrier coating of claim 1 , wherein the CMAS-resistant component includes at least 20 mole percent rare earth metal cations.5. The environmental barrier coating of wherein the rare earth hafnate is selected such that when the solubility limit of the rare earth hafnate in monoclinic hafnia is exceeded claim 1 , a pyrochlore phase is formed.6. The environmental barrier coating of claim 1 , wherein the CMAS-resistant component further includes hafnia.7. The environmental barrier coating of claim 6 , wherein the CMAS-resistant component includes about 40 single cation mole percent hafnium oxide claim 6 , about 20 single cation mole percent hafnium silicate claim 6 , and about 40 single cation mole percent rare-earth hafnate.8. The environmental barrier coating of claim 6 , wherein the CMAS-resistant component includes between about 60 and about 90 single cation mole percent hafnium silicate claim 6 , between about 5 and about 40 single cation mole percent rare-earth hafnate claim 6 , and up to about 5 single cation mole percent hafnium oxide.9. The environmental barrier ...

OXIDATION RESISTANT BOND COAT LAYERS, PROCESSES FOR COATING ARTICLES, AND THEIR COATED ARTICLES

A coated article including an article having a surface; an oxidation resistant bond coat layer deposited on the surface, the oxidation resistant bond coat layer comprising a healing silica matrix and at least one oxygen scavenger forming a metal silicide network dispersed within the healing silica matrix; and a top coat layer disposed upon the oxidation resistant bond coat layer, whereby the oxidation resistant bond coat layer is operable to seal a crack in the top coat layer. 1. A coated article , comprising:an article having a surface;an oxidation resistant bond coat layer deposited on the surface, the oxidation resistant bond coat layer comprising a healing silica matrix and at least one oxygen scavenger forming a metallic, intermetallic, or metal silicide network dispersed within the healing silica matrix; andan environmental protective top coat layer disposed upon the oxidation resistant bond coat layer, whereby the oxidation resistant bond coat layer is operable to repair a crack in the top coat layer.2. The coated article as recited in claim 1 , wherein the metallic claim 1 , intermetallic claim 1 , or metal silicide network is embedded in the silicon oxide based healing silica matrix claim 1 , the healing silica matrix contains glass phases having a viscosity of 10poise to 10poise at a temperature of 1 claim 1 ,292 F (700 C) to 3 claim 1 ,272 F (1 claim 1 ,800 C) to flow into the cracks.3. The coated article as recited in claim 1 , wherein the metallic claim 1 , intermetallic claim 1 , or metal silicide network comprises 30-90% by volume of the oxidation resistant bond coat layer.4. The coated article as recited in claim 1 , wherein interstices in the metallic claim 1 , intermetallic claim 1 , or metal silicide network is at least partially filled with the silica based healing matrix to protect the surface and provide the healing function.5. The coated article as recited in claim 1 , wherein the metallic claim 1 , intermetallic claim 1 , or metal silicide ...

Chemical and topological surface modification to enhance coating adhesion and compatibility

A process of coating a substrate containing silicon with an environmental barrier coating, comprising altering a surface of the substrate and applying an environmental barrier layer to the surface of the substrate.

Methods for manufacturing investment casting shells

An at least two step heating process is used to strengthen the shell of an investment casting mold including a refractory metal core. The first stage (46) may occur under otherwise oxidizing conditions at a low enough temperature to avoid substantial core oxidation. The second stage (56) may occur under essentially non-oxidizing conditions at a higher temperature.

Methods for manufacturing investment casting shells

An at least two step heating process is used to strengthen the shell of an investment casting mold including a refractory metal core. The first stage may occur under otherwise oxidizing conditions at a low enough temperature to avoid substantial core oxidation. The second stage may occur under essentially non-oxidizing conditions at a higher temperature.

Halogen-free trivalent chromium conversion coating

Trivalent chromium conversion coatings are provided on a metal substrate wherein the trivalent chromium conversion coating has a halogen content of 1 atom % maximum.

Hafnon and zircon environmental barrier coatings for silicon-based components

A method for coating a substrate includes spraying a combination of powders. The combination of powders includes: Hf 0.5 Si 0.5 O 2 ; Zr 0.5 Si 0.5 O 2 ; HfO 2 and, optionally, ZrO 2 . A molar ratio of said Hf 0.5 Si 0.5 O 2 and HfO 2 combined to said Zr 0.5 Si 0.5 O 2 and ZrO 2 (if present) combined is from 2:1 to 4:1. A molar ratio of said Hf 0.5 Si 0.5 O 2 to said HfO 2 is at least 1:3.

Safety elevator brake

(57)【要約】 【課題】 本発明の他の目的は、高摩擦係数かつ低摩耗 性を有し、高速及び荷重の多いエレベータへの使用のた めの信頼できるエレベータ安全制動装置を提供すること である。 【解決手段】 エレベータの安全制動装置は、基台と、 前記基台に設けれてエレベータ・ガイド・レールに接触 する摩擦面と、前記基台を備えたブレーキ・シュー２６ とを有しており、少なくとも摩擦面の一部は、おおよそ ９９．４重量％のモリブデンと、０．５重量％のチタン と、０．１重量％のジルコニウムから形成される合金か らなっている。前記安全制動装置は、エレベータかごを 停止させるために、ガイド・レールに向かって前記ブレ ーキ・シュー２６の摩擦材を押しつけるためのアクチュ エータに設置されている。

Investment casting cores

An investment casting core comprises a ceramic core element (206) and a refractory metal core element (200) retained relative to the ceramic core element. A rod (209) partially embedded in the ceramic core element ( 206) extends through an aperture in the refractory metal core element (200).

Additive manufacturing of metal matrix composite feedstock

Refactory metal core

Halogen-free trivalent chromium conversion coating

Trivalent chromium conversion coatings are provided on a metal substrate wherein the trivalent chromium conversion coating has a halogen content of 1 atom % maximum.

Elevator safety brake

(57)【要約】 【課題】 積載量の多い高速エレベータでの使用に適し たエレベータ安全制動機を提供する。 【解決手段】 エレベータかごを停止させるためのエレ バータ安全制動機１２では、エレベータガイドレール１ ６の面と接触して制動力を提供するブレーキシュー２５ の摩擦面に窒化ケイ素インサート３８が設けられてい る。窒化ケイ素インサート３８は、弾性材料からなる中 間部材４０を介して取り付けられており、この中間部材 ４０によって基部２６に対して弾性的に動作することが 可能となっている。窒化ケイ素材料を含む制動機の摩擦 面は、摩擦が一定して高く、かつ摩耗率が低いので、高 層ビルで運行される高速で積載量が多いエレベータに適 する。

Self-healing matrix for a ceramic composite

A method for forming a self-healing ceramic matrix composite (CMC) component (10) includes depositing a first self-healing particulate material (18a) in a first region of a CMC preform of the CMC component (10) and depositing a second self-healing particulate material (18b) having a different chemical composition than the first self-healing particulate material (18a) in a second region of the CMC preform distinct from the first region.

Environmental barrier coating

An environmental barrier coating includes a barrier layer which includes a matrix, diffusive particles, and gettering particles; and a calcium-magnesia alumina-silicate (CMAS)-resistant component. The CMAS-resistant component includes hafnium silicate and a rare earth hafnate. An article and a method of fabricating an article are also disclosed.

Process for the production of brush seals

Fluorine extraction process for fluoro-refractory coatings and articles manufactured according to said process

A process for extracting fluorine from a fluoro-refractory coating includes the steps of providing an article having a fluoro-refractory coating; treating hydrothermally the fluoro-refractory coating at a temperature and for a period time sufficient to liberate a quantity of fluoride from the fluoro-refractory coating; and drying a hydrothermally treated article.

Refractory metal core coatings

A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Refractory metal core wall thickness control

In accordance with the present invention, a casting system is provided which broadly comprises a core and a wax die spaced from said core, a refractory metal core having a first end seated within a slot in the core and a second end contacting the wax die for positioning the core relative to the wax die, and the refractory metal core having at least one of a mechanism for providing spring loading when closed in the wax die and a mechanism for mechanically locking the wax die to the core.

Method of weld repairing a component with a refractory metal backing material

The present invention relates to a method for repairing components such as blades used in turbine engines. The method comprises the steps of placing a piece of refractory metal material (16) over an area of the component to be repaired (12) and depositing a repair filler metal material (20) over the piece of refractory material (16) in an amount sufficient to repair the component and welding the repair filler metal material (20) in place. The refractory metal material (16) may be selected from the group consisting of niobium, tantalum, molybdenum, tungsten, a metal having a melting point higher than the melting point of nickel, and alloys thereof and may be uncoated or coated.

Refractory metal core

A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating comprises at least one oxide and a silicon containing material. In a second embodiment, the coating comprises an oxide selected from the group consisting of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating comprises a nitride selected from the group consisting of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Casting system for investment casting process

A casting system includes a core and a shell positioned relative to the core. A barrier coating is applied on at least one of the core and the shell, and may be applied to both the core and the shell. The barrier coating limits reaction between the casting system and a casting alloy.

Corrosion inhibiting additive

A corrosion resistant article includes an aluminum substrate having greate r than 0.25 wt% zinc, and a protective coating on the aluminum substrate. The protective coating includes a non-tungstate anodic corrosion inhibitor and a cathodic corrosion inhibitor.

Coating fabrication method for producing engineered microstructure of silicate-resistant barrier coating

A gas turbine engine article includes a substrate and a silicate-resistant barrier coating disposed on the substrate. The silicate-resistant barrier coating has an engineered microstructure that includes a refractory matrix formed of grains and calcium aluminosilicate additive (CAS additive) dispersed in grain boundaries between the grains.

Wear and friction control of metal rope and sheave interfaces

A coated sheave ( 24 ) for use in an elevator system in having at least one rope ( 22 ) and sheave combination, where the sheave has a predetermined shape and size for engagement with at least one rope in the elevator system. A coating ( 27 ) on the sheave has a wear coefficient of at least 80% less than the wear coefficient of the sheave without the coating.

Corrosion inhibiting coating composition for a Zn-containing aluminum alloy

A corrosion resistant article (10) includes an aluminum substrate (12) having greater than 0.25 wt% zinc, and a protective coating (14) on the aluminum substrate. The protective coating includes a non-tungstate anodic corrosion inhibitor (16) and a cathodic corrosion inhibitor (18).

Solid-state method for forming an alloy and article formed

A solid-state method for forming an alloy includes providing a powder that has heterogeneous particles with a ratio, by weight, of an amount of nickel to an amount of a metal. The ratio is selected in accordance with a compositional ratio that can substantially bear a nickel intermetallic precipitate of the nickel and the metal. The heterogeneous particles are then consolidated and thermally treated to interdiffuse the nickel and the metal. The interdiffused nickel and metal are then precipitation treated to precipitate the nickel intermetallic.

Ceramic matrix composite component and method of making the same

A method of making a ceramic matrix composite according to an exemplary embodiment of this disclosure, among other possible things includes forming a ceramic matrix composite component by infiltrating an array of ceramic-based fibers with a ceramic-based matrix. The array of ceramic-based fibers forms a surface that includes gaps between adjacent ones of the fibers. The method also includes applying a paste including filler particles and filler matrix in a carrier fluid to the surface of the ceramic-based fibers that includes the gaps such that the paste fills the gaps and removing the carrier fluid to leave behind a filler including the filler particles and the filler matrix in the gaps. A ceramic matrix composite component is also disclosed.

Environmental barrier coating and method of making the same

A method of making spherical gettering particles for an environmental barrier coating according to an exemplary embodiment of this disclosure, among other possible things includes spraying liquid preceramic polymer into a chamber via a nozzle to form liquid droplets, curing the liquid droplets to form spherical particles in the chamber, and converting the spherical particles to spherical ceramic gettering particles in a fluidized bed. A method of making spherical gettering particles for an environmental barrier coating and an article are also disclosed.

物品用バリア層、および物品

【課題】ガスタービンエンジンに使用されるような物品用バリア層を提供する。【解決手段】本開示の例示的な実施形態による物品用バリア層は、とりわけマトリックスと、マトリックス中に配置された拡散粒子と、マトリックス中に配置されたゲッタリング粒子とを含むボンドコートを含む。ゲッタリング粒子の組成は、下記化学反応による反応生成物である。TIFF2024012195000020.tif50166TIFF2024012195000021.tif50166【選択図】図２

Reparaturverfahren für superlegierungen und inserts

Thermally stable thin-film reflective coating and coating process

A gas turbine engine component having a substrate; a thermal barrier coating on the substrate having a porous microstructure; and a reflective layer conforming to the porous microstructure of the thermal barrier coating, wherein the reflective layer comprises a conforming nanolaminate defined by alternating layers of platinum group metal materials selected from the group consisting of platinum group metal-based alloys, platinum group metal intermetallic compounds, mixtures of platinum group metal with metal oxides and combinations thereof. A capping layer can be added over the reflective layer. A supporting layer can be added between the reflective layer and the thermal barrier coating. A process is also disclosed.

Tube structures for heat exchanger

A heat exchanger includes a plurality of fins and a plurality of tubes passing a fluid therethrough, extending through the plurality of fins and radially expanded into an interference fit therewith. At least one tube of the plurality of tubes includes an outer diameter, an inner diameter, and a plurality of ridges extending from the inner diameter inwardly into an interior of the tube. A tube internal surface area per unit of length of the tube multiplied by the ratio of the outer diameter and tube wall thickness is equal to or greater than about 30.0.

Ceramic matrix composite component and method of making the same

A method of making a ceramic matrix composite according to an exemplary embodiment of this disclosure, among other possible things includes forming a ceramic matrix composite component (100) by infiltrating an array (102) of ceramic-based fibers (104) with a ceramic-based matrix (106). The array (102) of ceramic-based fibers (104) forms a surface (108) that includes gaps (110) between adjacent ones of the fibers (104). The method also includes applying a paste including filler particles (114) and filler matrix (116) in a carrier fluid to the surface (108) of the ceramic-based fibers (104) that includes the gaps (110) such that the paste fills the gaps (110) and removing the carrier fluid to leave behind a filler (112) including the filler particles (114) and the filler matrix (116) in the gaps (110). A ceramic matrix composite component (100) is also disclosed.

Protective coating

A barrier layer for an article according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat comprising a matrix, diffusive particles disposed in the matrix, and gettering particles disposed in the matrix. The composition of the gettering particles is a reaction product of the chemical reaction of Equation 1 defined by Equation 2: SiwOxCyNz+ξO2=wSiO2+yCO+z2N2ξ=2w+y−x2A barrier layer is also disclosed.

Environmental barrier coating

A coating (116) according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat (102) including gettering particles (108) and diffusive particles (110) dispersed in a matrix (106); a top coat (114) disposed over the bond coat (102), the top coat (114) includes metal silicate particles (120); and an intermediate layer (118) between the bond coat (102) and the top coat (114). The intermediate layer (118) includes hafnium silicate particles and matrix (106). A concentration of metal silicate in the intermediate layer (118) is less than a concentration of metal silicate in the top coat (114). An article (100) is also disclosed.

Environmental barrier coating and method of repairing the same

A method of repairing a coating on an article according to an exemplary embodiment of this disclosure, among other possible things includes defining a work area surrounding a discontinuity in the coating, the coating including undisturbed bond coat and undisturbed top coat; removing coating material within the work area; applying a slurry containing bond coat constituents in a carrier fluid to the work area; curing the slurry to form a repaired bond coat; applying a slurry containing top coat constituents in a carrier fluid to the work area; and curing the slurry to form a repaired top coat. A method of repairing a coating on an article and an article are also disclosed.

Environmental barrier coating

An article according to an exemplary embodiment of this disclosure, among other possible things includes a substrate and a barrier layer on the substrate. The barrier layer includes a bond coat comprising a matrix, diffusive particles disposed in the matrix, and gettering particles disposed in the matrix; and a topcoat including a constituent that is reactive with calcium-magnesium-alumino-silicate (CMAS). An article and a method applying a calcium-magnesium-alumino-silicate (CMAS)-resistant topcoat are also disclosed.

Environmental barrier coating and method of making the same

A feedstock for spray deposition of a coating includes particles each including a particle core and a coating. The particle core is a gettering particle. The coating includes at least one of diffusive material, precursor diffusive material, matrix material, and precursor matrix material. A method of coating a substrate is also disclosed.

Environmental barrier coating and method of making the same

A method of making spherical gettering particles for an environmental barrier coating according to an exemplary embodiment of this disclosure, among other possible things includes spraying liquid preceramic polymer into a chamber via a nozzle to form liquid droplets or a stream of liquid droplets, curing the liquid droplets to form spherical particles in the chamber, and converting the spherical particles to spherical ceramic gettering particles in either a fluidized bed or by directing the stream of cured particles through a torch. An environmental barrier coating and an article are also disclosed.

Environmental barrier coating

An article according to an exemplary embodiment of this disclosure, among other possible things includes a substrate and a barrier layer on the substrate. The barrier layer includes a bond coat comprising a matrix, diffusive particles disposed in the matrix, and gettering particles disposed in the matrix; a topcoat; and a porous interlayer disposed between the topcoat and the bond coat. The porous interlayer has a porosity that is greater than a porosity of the topcoat. A slurry composition for applying an interlayer to an article and method of applying a top coat to an article are also disclosed.

Environmental barrier coating

A coating according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat including gettering particles and diffusive particles dispersed in a matrix, a top coat disposed over the bond coat, and an intermediate layer between the bond coat and the top coat. The intermediate layer includes non-silicate oxide particles dispersed in a matrix. An article and a method of protecting a ceramic-based substrate are also disclosed.

Environmental barrier coating and method of making the same

A method of applying a top coat to an article according to an exemplary embodiment of this disclosure, among other possible things includes providing an article having a bond coat; applying a slurry directly onto the bond coat, the slurry including particles of a top coat material and at least one sintering aid in a carrier fluid; and sintering the top coat. A slurry composition for applying a top coat to an article is also disclosed.

Environmental barrier coating and method of forming the same

A method of applying a coating to a substrate includes forming a slurry by mixing elemental precursors of gettering particles, diffusive particles, matrix material, and a carrier fluid; applying the slurry to a substrate; and sintering the slurry to form a composite material. The sintering causes the elemental precursors to react with one another to form gettering particles. An article is also disclosed.

Environmental barrier coating with porous bond coat layer

A gas turbine engine article includes a silicon-containing ceramic substrate and an environmental barrier coating (EBC) system disposed on the substrate. The EBC system includes, from the substrate, a dense bond coat layer, a porous bond coat layer, and a topcoat layer in contact with the porous bond coat layer. The dense bond coat layer and the porous bond coat layer each include a silica matrix and oxygen-scavenging gas-evolution particles dispersed through the silica matrix. The porous bond coat layer includes engineered pores.

Environmental barrier coating with thermal properties

An article according to an exemplary embodiment of this disclosure, among other possible things includes a substrate and a barrier layer on the substrate. The barrier layer includes a bond coat comprising a matrix, diffusive particles disposed in the matrix, and gettering particles disposed in the matrix. At least about 10% of the gettering particles are in a crystalline phase. The article also includes a top coat. An article is also disclosed.

Environmental barrier coating

A coating (116) according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat (102) including gettering particles (108) and diffusive particles (110) dispersed in a matrix (106), a top coat (114) disposed over the bond coat (102), and an intermediate layer (118) between the bond coat (102) and the top coat (114). The intermediate layer (118) includes non-silicate oxide particles (120) dispersed in a matrix (106). An article (100) and a method of protecting a ceramic-based substrate (104) are also disclosed.

Environmental barrier coating and method of forming the same

A method of applying a coating to a substrate includes forming a slurry by mixing elemental precursors of gettering particles, diffusive particles, matrix material, and a carrier fluid; applying the slurry to a substrate; and sintering the slurry to form a composite material. The sintering causes the elemental precursors to react with one another to form gettering particles. An article is also disclosed.

Environmental barrier coating

A coating according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat including gettering particles and diffusive particles dispersed in a matrix; a top coat disposed over the bond coat, the top coat includes metal silicate particles; and an intermediate layer between the bond coat and the top coat. The intermediate layer includes hafnium silicate particles and matrix. A concentration of metal silicate in the intermediate layer is less than a concentration of metal silicate in the top coat. An article is also disclosed.

Method of coating metallic powder particles and sytem therefor