A layered structure having high adhesive properties, and high hardness or excellent transparency, is prepared on a base material such as a resin. A layered structure including: an organic-inorganic hybrid member containing a primary inorganic particle and an organic polymer covalently bound to each other, wherein the primary inorganic particle forms a network containing the polymer; and a particle aggregate layer containing a secondary particle which is deposited on the organic-inorganic hybrid member and is composed of an inorganic material or a metallic material; wherein in the organic-inorganic hybrid member, the primary inorganic particle and the secondary particle have different crystal particle sizes.

A layered structure having high adhesive properties, and high hardness or excellent transparency, is prepared on a base material such as a resin. A layered structure including: an organic-inorganic hybrid member containing a primary inorganic particle and an organic polymer covalently bound to each other, wherein the primary inorganic particle forms a network containing the polymer; and a particle aggregate layer containing a secondary particle which is deposited on the organic-inorganic hybrid member and is composed of an inorganic material or a metallic material; wherein in the organic-inorganic hybrid member, the primary inorganic particle and the secondary particle have different crystal particle sizes.

Systems and methods are provided for applying cold spray erosion protection to an airfoil. One embodiment is a method for applying an abrasion coating to a fiber-reinforced composite substrate. The method includes applying a bond layer to the fiber-reinforced composite substrate by emitting, with a supersonic nozzle of a High Pressure Cold Spray (HPCS) system, a first gas stream including a first metal powder at a first speed below supersonic speed. The method further includes applying a cold spray deposit layer to the bond layer by emitting, with the supersonic nozzle, a second gas stream including a second metal powder at a second speed above supersonic speed.

Multiple processes for preparing porous articles are described. The porous articles can be in a wide array of shapes and configurations. The methods include providing a soluble material in particulate form and forming a packed region from the material. The methods also include contacting a flowable polymeric material with the packed region such that the polymeric material is disposed in voids in the packed region. The polymeric material is then at least partially solidified. The soluble material is then removed such as by solvent washing to thereby produce desired porous articles. Also described are systems for performing the various processes.

Multiple processes for preparing porous articles are described. The porous articles can be in a wide array of shapes and configurations. The methods include providing a soluble material in particulate form and forming a packed region from the material. The methods also include contacting a flowable polymeric material with the packed region such that the polymeric material is disposed in voids in the packed region. The polymeric material is then at least partially solidified. The soluble material is then removed such as by solvent washing to thereby produce desired porous articles. Also described are systems for performing the various processes.

A material applicator for controlling application of at least one material on a substrate includes a housing and an array plate with an applicator array positioned within the housing. The applicator array has a plurality of micro-applicators and each of the plurality of micro-applicators has an ultrasonic transducer, a material inlet, a reservoir, and a micro-applicator plate with a plurality of apertures. The applicator plate is in mechanical communication with the ultrasonic transducer such that at least one material is ejected through the plurality of apertures as atomized droplets when the ultrasonic transducer vibrates the micro-applicator plate.

A material applicator for controlling application of at least one material on a substrate includes a housing and an array plate with an applicator array positioned within the housing. The applicator array has a plurality of micro-applicators and each of the plurality of micro-applicators has an ultrasonic transducer, a material inlet, a reservoir, and a micro-applicator plate with a plurality of apertures. The applicator plate is in mechanical communication with the ultrasonic transducer such that at least one material is ejected through the plurality of apertures as atomized droplets when the ultrasonic transducer vibrates the micro-applicator plate.

Apparatuses and methods related to improving environmental protection and waste collection from application of deposition material using portable systems that are easier for operators to use on surfaces such as ship hulls are provided. Embodiments include a portable and repositionable deposition material applicator enclosure and application system for applying deposition material on a substrate employing non-adherent deposition material waste removal and selective enclosure coupling and decoupling structures or systems employing magnetic and suction or differential pressure based forces.

Apparatuses and methods related to improving environmental protection and waste collection from application of deposition material using portable systems that are easier for operators to use on surfaces such as ship hulls are provided. Embodiments include a portable and repositionable deposition material applicator enclosure and application system for applying deposition material on a substrate employing non-adherent deposition material waste removal and selective enclosure coupling and decoupling structures or systems employing magnetic and suction or differential pressure based forces.

An apparatus includes a component having an edge feature that has a radius of curvature. The apparatus includes an underlayer arranged over the edge feature and configured to increase the radius of curvature of the edge feature. The apparatus includes a powder coating arranged over the component and over the underlayer to form a continuous layer. The underlayer is configured to remain under the powder coating. The underlayer helps the powder coating achieve a more uniform thickness over the edge feature. The apparatus is formed by applying an underlayer to a first region of the component to form an underlaid component. The first region includes the edge feature. A powder coating is applied to the underlaid component. A masking layer may be applied to a region other than the first region, and after powder coating, the masking may be removed to expose a surface of the component.