A method of manufacturing a device includes thermally spraying tungsten carbine in feedstock that does not include Cobalt but that includes Nickel, Copper, or a Nickel-Copper alloy, the method improves the base coating toughness, anticorrosion, and antifouling properties for high load application in sea water and brackish water environments. Additionally, a Cobalt-free material lowers material costs and reduces the global demand of Cobalt. Providing a topcoat of a Silicon-doped DLC significantly reduces the topcoat brittleness of common DLC failures such as “egg shell” in high stress applications. Thus, high hardness, low friction applications may be tailored in high stress applications.

A thermal spray particle is substantially spherical, and contains iron and aluminum. An amount of aluminum contained in the thermal spray particle is in a range of 32 wt % to 48 wt %. The thermal spray particle includes a first region, in which a concentration of aluminum is in a range of 22 wt % to 37 wt %; and a second region, in which a concentration of aluminum is in a range of 40 wt % to 50 wt %.

A thermal spray particle is substantially spherical, and contains iron and aluminum. An amount of aluminum contained in the thermal spray particle is in a range of 32 wt % to 48 wt %. The thermal spray particle includes a first region, in which a concentration of aluminum is in a range of 22 wt % to 37 wt %; and a second region, in which a concentration of aluminum is in a range of 40 wt % to 50 wt %.

The present disclosure relates to a method of manufacturing an ion-selective sensor element for a potentiometric sensor, the sensor element having a sensor element body and at least one glass layer arranged on the sensor element body, the method comprising applying the at least one glass layer to the sensor element body by means of a thermal spraying method, in which a powder of glass particles is sprayed onto the sensor element body.

A method for preparing a thermal barrier coating (TBC) material includes: spraying a metal mixture onto a surface of an alloy using supersonic flame spraying or explosive spraying to form a bottom layer; spraying an yttria-stabilized zirconia (YSZ) precursor sol onto the bottom layer using liquid plasma spraying to form an intermediate layer; and spraying a ceramic composite including SiO.sub.2 and La—Ce—Zr—O using plasma spraying or explosive spraying to form a surface layer.

A method for preparing a thermal barrier coating (TBC) material includes: spraying a metal mixture onto a surface of an alloy using supersonic flame spraying or explosive spraying to form a bottom layer; spraying an yttria-stabilized zirconia (YSZ) precursor sol onto the bottom layer using liquid plasma spraying to form an intermediate layer; and spraying a ceramic composite including SiO.sub.2 and La—Ce—Zr—O using plasma spraying or explosive spraying to form a surface layer.

A method for forming a hydrophobic coating on a substrate by a thermal spray deposition process is described. The method may comprise feeding a thermal spray apparatus with a coating precursor consisting of particles having an initial particle morphology, and heating the particles with the thermal spray apparatus to cause the particle to at least partially melt. The method may further comprise accelerating the particles towards the substrate, and forming the hydrophobic coating on the substrate by allowing the particles to impact the substrate in a partially melted state in which a fraction of the initial particle morphology of at least some of the particles is retained.

A method for forming a hydrophobic coating on a substrate by a thermal spray deposition process is described. The method may comprise feeding a thermal spray apparatus with a coating precursor consisting of particles having an initial particle morphology, and heating the particles with the thermal spray apparatus to cause the particle to at least partially melt. The method may further comprise accelerating the particles towards the substrate, and forming the hydrophobic coating on the substrate by allowing the particles to impact the substrate in a partially melted state in which a fraction of the initial particle morphology of at least some of the particles is retained.

Disclosed herein are embodiments of a powder feedstock, such as for bulk welding, which can produce welds. The powder feedstock can include high levels of boron, and may be improved over previously used cored wires. Coatings can be formed from the powder feedstock which may have high hardness in certain embodiments, and low mass loss under ASTM standards.

A method for preparing a thermal barrier coating (TBC) material includes: spraying a metal mixture onto a surface of an alloy using supersonic flame spraying or explosive spraying to form a bottom layer; spraying an yttria-stabilized zirconia (YSZ) precursor sol onto the bottom layer using liquid plasma spraying to form an intermediate layer; and spraying a ceramic composite including SiO.sub.2 and La—Ce—Zr—O using plasma spraying or explosive spraying to form a surface layer.