A bond coating material providing unexpectedly high thermal cyclic fatigue resistance and sulfidation resistance, and unexpectedly prolonged thermal cycle life in high temperature environments of gas turbine engine components with and without the presence of sulfur contains: a) 10% to 30% by weight chromium, b) at least one of tantalum and molybdenum in a total amount of 3% to 15% by weight, c) 5% to 13% by weight aluminum, d) 0.1% to 1.4% by weight silicon, e) 0.1% to 0.8% by weight yttrium, f) 0% to 1.2% by weight carbon, g) 0% to 1% by weight dysprosium, h) 0% to 1% by weight cerium, i) the balance being nickel, and the percentages of a) to i) adding up to 100% by weight. The total amount of tantalum and molybdenum, and the amounts of aluminum and silicon are each critical for avoiding delamination of a top coat from a bond coat.

An apparatus for coating a surface of a substrate includes an evaporant source disposed within an open environment including air at atmospheric pressure. The evaporant source includes a coating material. The apparatus further includes an energy beam source disposed within the open environment and configured to emit at least one energy beam that impinges on an emission region of the evaporant source to form a vapour plume at the emission region. The vapour plume includes the coating material of the evaporant source. The apparatus further includes a fixture configured to position the evaporant source relative to the substrate within the open environment, such that a maximum distance between the emission region of the evaporant source and the surface of the substrate is less than or equal to 10 cm.

A composite substrate comprising a mesh layer and a composite material layer is provided, wherein the mesh layer comprises a mesh material and an adhesive, said adhesive permeating the mesh material and adhering the mesh material directly to a surface of the composite material layer. A metal-coated composite substrate is provided. The metal-coated composite substrate comprises a composite substrate, as defined in the section above, and a metal layer covering a side of the mesh layer opposite the composite layer. Furthermore, a method for producing the composite substrate is provided. Moreover, a method for producing the metal-coated composite substrate is provided.

Materials and a process for forming a protective oxide coating. The high temperature coating system (108) includes at least a thermal barrier coating layer (104) and a thermally stable, deposit resistant protective layer (106) on the thermal barrier coating layer (104).

A composition, a machine component coated with the same, and a method of coating the machine component are provided. The composition includes a CoNiCrAlY alloy, where three or more elements of the CoNiCrAlY alloy are present in equimolar amounts, one of the three or more elements of the CoNiCrAlY alloy being aluminum (Al), and where a molar fraction of Al is between about 0.20 and about 0.25. The composition further includes a transition metal boride including at least one of: cobalt boride (Co.sub.2B), titanium boride (TiB.sub.2), zirconium boride (ZrB.sub.2), tantalum boride (TaB.sub.2), niobium boride (NiB.sub.2), or molybdenum boride (Mo.sub.2B), and a refractory alloy.

A sprayed coating for a sliding member of the present invention includes a ferrous alloy containing iron (Fe) as a major ingredient. The sprayed coating for the sliding member containing 10 mass % or more and 20 mass % or less of chromium (Cr), and 0.1 mass % or more and 0.5 mass % or less of silicon (Si) and having the content rate of an oxide in the sprayed coating of 1 area % or less has corrosion resistance with improved seizure resistance.

A sprayed coating for a sliding member of the present invention includes a ferrous alloy containing iron (Fe) as a major ingredient. The sprayed coating for the sliding member containing 10 mass % or more and 20 mass % or less of chromium (Cr), and 0.1 mass % or more and 0.5 mass % or less of silicon (Si) and having the content rate of an oxide in the sprayed coating of 1 area % or less has corrosion resistance with improved seizure resistance.

A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

A method of applying a long lasting wear-resistant coating on a Yankee drying cylinder is described, whereby the method includes: providing a Yankee drying cylinder having a cylindrical shell with a circular cross-section and an outer surface; and performing a thermal spray operation to form a wear-resistant coating layer on the outer surface of the Yankee drying cylinder during which thermal spray operation coating feedstock is fed to at least one spray device, heated to become plastic and/or semi-molten and/or molten and sprayed onto the outer surface of the Yankee drying cylinder to form the wear-resistant coating layer. The coating feedstock for the thermal spray operation consists of a specific set of elements, by percent weight, with the remainder being iron and impurities. Coatings and Yankee cylinders with such coatings are also disclosed.