A wind turbine blade includes a base member formed of FRP and having a blade shape, an intermediate layer arranged on the base member and formed of metal, cermet, ceramic, or a mixture of at least one thereof and resin as a major constituent, and an erosion-resistant overcoat arranged on the intermediate layer and formed of a spray film having a porosity of 5% or lower.

A coated component including a slotted ceramic coating with a reactive phase coating disposed thereon for improved resistance to environmental contaminant compositions, along with methods of its formation, is provided. The coated component may include a substrate defining a surface, a ceramic coating disposed on the surface of the substrate, and a reactive phase coating disposed on the layer of environmental contaminant compositions. The ceramic coating includes a plurality of slots disposed in the ceramic coating forming segments of ceramic coating material.

Disclosed herein is a method for assessing a flow a sprayed coating, including the steps of spraying a coating onto a surface and capturing a plurality of images of the sprayed surface at a predetermined frequency within a predetermined interval of time, and a computer program product for assessing a flow of a sprayed coating.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

A wind turbine blade includes a base member formed of FRP and having a blade shape, an intermediate layer arranged on the base member and formed of metal, cermet, ceramic, or a mixture of at least one thereof and resin as a major constituent, and an erosion-resistant overcoat arranged on the intermediate layer and formed of a spray film having a porosity of 5% or lower.

A composite structure with an aluminum-based alloy layer containing boron carbide and a manufacturing method thereof are provided. The composite structure includes a substrate with an open hole in that surface and the aluminum-based alloy layer containing boron carbide. The aluminum-based alloy layer is disposed in the open hole and contains aluminum, boron, carbon, and oxygen, wherein the content of aluminum is between 4 at. % and 55 at. %, the content of boron is between 9 at. % and 32 at. %, the content of carbon is between 13 at. % and 32 at. %, the content of oxygen is between 2 at. % and 38 at. %, and the ratio of the content of boron to carbon is between 0.3 and 2.7.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

The purpose of the present invention is to provide an alloy product which has both of high corrosion resistance enough to withstand severe corrosive/high-temperature environments and mechanical properties equivalent to or better than those of stainless steel, and which can be produced at lower cost than a Ni-based alloy. The Cr—Fe—Ni-based alloy product of the present invention is a product produced using a Cr—Fe—Ni-based alloy containing Cr as a largest-content component, wherein the product has such a microstructure that a dual-phase structure having a ferrite phase and an austenite phase coexisting therein serves as a matrix phase and an L1.sub.2-type Ni-based intermetallic compound phase is dispersed and precipitated in the austenite phase.