A thin-walled metal part, and a method to fabricate such a part out of various alloys. A plurality of layers are formed, each of the layers being formed on a polymer template or on a previously formed layer. A homogenizing heat treatment is used to cause chemical elements in the layers to interdiffuse, to form a single continuous layer with a substantially uniform alloy composition.

A thin-walled metal part, and a method to fabricate such a part out of various alloys. A plurality of layers are formed, each of the layers being formed on a polymer template or on a previously formed layer. A homogenizing heat treatment is used to cause chemical elements in the layers to interdiffuse, to form a single continuous layer with a substantially uniform alloy composition.

A process of treating a component includes mechanically removing surface debris from a base coating of the component, identifying at least one surface feature in the base coating, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A process of treating a gas turbine component includes mechanically removing surface debris from a base coating of the gas turbine component, identifying at least one surface feature in the base coating of corrosion pits, dents, spalls, and combinations thereof, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A treated gas turbine component includes a gas turbine component substrate and a base coating on the gas turbine component substrate having at least one healed surface feature. The healed surface feature includes an overlay coating layer on the base coating.

A process of treating a component includes mechanically removing surface debris from a base coating of the component, identifying at least one surface feature in the base coating, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A process of treating a gas turbine component includes mechanically removing surface debris from a base coating of the gas turbine component, identifying at least one surface feature in the base coating of corrosion pits, dents, spalls, and combinations thereof, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A treated gas turbine component includes a gas turbine component substrate and a base coating on the gas turbine component substrate having at least one healed surface feature. The healed surface feature includes an overlay coating layer on the base coating.

A coating process for applying a bifurcated coating to an article is disclosed including applying an aluminizing slurry to a first portion of the article, applying a chromizing slurry to a second portion of the article, and simultaneously heat treating the article, the aluminizing slurry, and the chromizing slurry. Heat treating the aluminizing slurry forms an aluminide coating on the first portion of the article and an aluminide diffusion zone between the article and the aluminide coating. Heat treating the chromizing slurry forms a chromide coating on the second portion of the article and a chromide diffusion zone between the article and the chromide coating. The first portion and the second portion are both maintained in an unmasked state while applying the aluminizing slurry and the chromizing slurry and during the heat treating.

A method of forming a protective coating. The method includes providing a substrate including at least one chemical element and a surface; forming a basecoat composition including an aluminium phase including aluminium;

applying the basecoat composition on the surface of the substrate to form a basecoat layer; heating the basecoat layer to a first temperature for a predetermined period of time; applying a glow discharge plasma on the basecoat layer; and heating the basecoat layer to a second temperature greater than the first temperature, in order to activate an exothermic reaction between at least the aluminium phase of the basecoat layer and the at least one chemical element of the substrate, wherein the exothermic reaction forms the protective coating on the surface of the substrate.

The present invention relates to a slip for producing an aluminum diffusion layer which comprises an Al-containing powder and an Si-containing powder and a binder, the slurry further comprising an Al-containing powder the powder particles of which are coated with Si. The invention further relates to a process for producing an aluminum diffusion layer, comprising the following steps: providing a slurry according to any one of the preceding claims, applying the slurry to a component surface on which the aluminum diffusion layer is to be created, drying and/or curing by way of a heat treatment at a first temperature, and diffusion annealing at a second temperature.

A coating system for a surface of a superalloy component is provided. The coating system includes a MCrAlY coating on the surface of the superalloy component, where M is Ni, Fe, Co, or a combination thereof. The MCrAlY coating generally has a higher chromium content than the superalloy component. The MCrAlY coating also includes a platinum-group metal aluminide diffusion layer. The MCrAlY coating includes Re, Ta, or a mixture thereof. Methods are also provided for forming a coating system on a surface of a superalloy component.

A slurry and a coating method are provided. The slurry includes, by weight, between 10% and 40% metal powder, between 10% and 15% activator, between 10% and 20% adhesive, between 10% and 20% thickener, up to 30% ceramic, and up to 25% binder. The coating method includes providing a slurry including, by weight, between 10% and 40% metal powder, between 10% and 15% activator, between 10% and 20% adhesive, between 10% and 20% thickener, up to 30% ceramic, and up to 25% organic polymer binder, providing a substrate, applying the slurry over a surface of the substrate to form a slurry coating, drying the slurry coating over the substrate, baking the substrate and the slurry coating, and curing the slurry coating over the substrate. The curing the slurry coating over the substrate transfers metal elements of the metal powder in the slurry to the substrate to form a coating on the substrate.

A facile method is based on a pack-cementation process using large-area copper foil instead of copper powder. By controlling a pack-cementation time and an amount of alloying element (e.g., aluminum), a hierarchical microporous or nanoporous copper can be created. When coated with tin active material, the hierarchical microporous or nanoporous copper can be used as an advanced lithium-ion battery anode. A coin-cell test exhibited a four-fold higher areal capacity (e.g., 7.4 milliamp-hours per square centimeter without any performance degradation up to 20 cycles) as compared to a traditional graphite anode.