The use of a physical mixture of partially stabilized and fully stabilized zirconium oxide powder for producing a thermal barrier coating results in good thermal barrier properties and good mechanical properties is provided.

An AlFe alloy coated steel sheet includes a base steel sheet and an alloy coating layer, wherein the base steel sheet includes, by wt %, C: 0.1%0.5%, Si: 0.01%2%, Mn: 0.01%10%, P: 0.001%0.05%, S: 0.0001%0.02%, Al: 0.001%1.0%, N: 0.001%0.02%, and the balance of Fe and other impurities, wherein the alloy coating layer includes: an AlFe alloy layer I formed on the base steel sheet and having a Vickers hardness of 200800 Hv; an AlFe alloy layer III formed on the AlFe alloy layer I and having a Vickers hardness of 7001200 Hv; and an AlFe alloy layer II formed in the AlFe alloy layer III continuously or discontinuously in a length direction of the steel sheet, and having a Vickers hardness of 400900 Hv, wherein an average oxygen content at a depth of 0.1 m from a surface of the oxide layer is 20% or less by weight.

A piston for a diesel engine is provided. The piston includes a thermal barrier coating applied to a crown formed of steel. A layer of a metal bond material is first applied to a combustion surface of the crown, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by a thermal spray process or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., based on the total volume of the thermal barrier coating, a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m.Math.K.

A component for an engine is provided. The component includes a thermal barrier coating applied to a body portion formed of metal, such as steel or another ferrous or iron-based material. According to one embodiment, a bond layer of a metal is applied to the body portion, followed by a mixed layer of metal and ceramic with a gradient structure, and then optionally a top layer of metal. The thermal barrier coating can also include a ceramic layer between the mixed layer and top layer, or as the outermost layer. The ceramic includes at least one of ceria, ceria stabilized zirconia, yttria, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating can be applied by thermal spray. The thermal barrier coating preferably has a thickness less than 200 microns and a surface roughness Ra of not greater than 3 microns.

A superalloy target wherein the superalloy target has a polycrystalline structure of random grain orientation, the average grain size in the structure is smaller than 20 m, and the porosity in the structure is smaller than 10%. Furthermore, the invention includes a method of producing a superalloy target by powder metallurgical production, wherein the powder-metallurgical production starts from alloyed powder(s) of a superalloy and includes the step of spark plasma sintering (SPS) of the alloyed powder(s).

A coated article includes a substrate, a functional layer over at least a portion of the substrate, and a protective coating over at least a portion of the functional layer, wherein an uppermost layer of the functional layer is a metal oxide layer, and wherein the protective coating comprises a metal nitride layer and a metal oxynitride layer that is disposed between and in contact with at least part of the metal nitride layer and the metal oxide layer of the functional layer.

Extreme ultraviolet (EUV) mask blanks, methods for their manufacture and production systems therefor are disclosed. The EUV mask blanks comprise a substrate; a multilayer stack of reflective layers on the substrate; a capping layer on the multilayer stack of reflecting layers; and an absorber layer on the capping layer, the absorber layer made from an alloy of tantalum and nickel.

A method for manufacturing a gun barrel with a cold spray process. The method includes the use of a mandrel having a tubular body and being made of a material with properties suited to use with gun barrel manufacture and materials and cold spray processes. The gun barrel includes a liner, one or more structural layers and an outer jacket. The mandrel is dissolved in a chemical process during manufacture of the gun barrel.

A coating system for a turbine engine component is disclosed. The coating system includes a substrate, an optional bond coat, a synthetic oxide layer and a top coat. The synthetic oxide layer is formed by atomic layer deposition and includes two or more oxides.

A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material is first applied, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m.Math.K.