Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer, along with tunable coatings made from the disclosed formulations and methods for coating installed fasteners, and fasteners, fastener/substrate interfaces and substrates coated with the tunable thermoplastic polymer coatings.

A system and method are provided to create porous surface coatings. In use, a method is included for receiving, at a plasma spray torch, inputs comprising metallic particles and carbon particles, using the plasma spray torch to cause in-situ nucleation of the inputs to synthesize carbon-containing composite materials, and flowing the synthesized carbon-containing composite materials onto a substrate. Some or all of the synthesized carbon-containing composite materials may include a surface layer and/or a bonding layer. Additionally, the method may include tuning the inputs based on tuning characteristics, the tuning characteristics including one or more of: porosity, heat transfer, or resistance to corrosion. Further, the method may include tuning the inputs to optimize temperature redistribution across a surface layer of some or all of the synthesized carbon-containing composite materials.

A nozzle for a cold spray deposition apparatus includes a convergent section defined about a nozzle inlet, a divergent section defined about a nozzle outlet, and a surface treatment that projects from an exterior of the divergent section, where an interior of the divergent section conveys a powder material received from the convergent section.

A nozzle for a cold spray deposition apparatus includes a convergent section defined about a nozzle inlet, a divergent section defined about a nozzle outlet, a cooling input port, a cooling output port, and a cooling channel wrapped around the divergent section, the cooling channel fluidly coupled to the cooling input port and the cooling output port.

An apparatus and method perform supersonic cold-spraying to deposit N and P-type thermoelectric semiconductor, and other polycrystalline materials on other materials of varying complex shapes. The process developed has been demonstrated for bismuth and antimony telluride formulations as well as Tetrahedrite type copper sulfosalt materials. Both thick and thin layer thermoelectric semiconductor material is deposited over small or large areas to flat and highly complex shaped surfaces and will therefore help create a far greater application set for thermoelectric generator (TEG) systems. This process when combined with other manufacturing processes allows the total additive manufacturing of complete thermoelectric generator based waste heat recovery systems. The processes also directly apply to both thermoelectric cooler (TEC) systems, thermopile devices, and other polycrystalline functional material applications.

A fluid tight, fully-densified, coating is prepared by a High Velocity Oxygen Fuel (HVOF) process that dilutes oxygen with an inert gas. The inert gas is pre-mixed with oxygen prior to the oxygen entering a combustion chamber. The resultant flame temperature is lowered a controlled amount to eliminate, minimize or reduce oxidation of power feedstock that is injected into the thermal spray torch. The ability to reduce the flame temperature allows a relatively smaller particle feedstock to be deposited without significant oxidation. The dilution process creates an as-deposited fully-dense, fluid tight coating.

An article may include a substrate including a ceramic matrix composite (CMC); a composite coating layer including a first coating material that includes a rare-earth disilicate and a second coating material that includes at least one of a rare-earth monosilicate, a CMAS-resistant material, or a high-temperature dislocating material, where the second coating material forms a substantially continuous phase in the composite coating layer.

A thermal spray apparatus to apply coatings to external and internal surfaces in restricted areas is provided. The apparatus includes: a fuel input line; an oxidizing gas input line; coolant input and outlet; a combustion chamber that facilitates primary combustion; a diverging section that splits the primary combustion flow into two or more streams; an elbow section that redirects the combustion streams; a convergent/divergent nozzle; a convergence section that recombines the combustion streams into a single combustion stream within an injection zone of the convergent/divergent nozzle; and a feedstock injector for the injection of feedstock material for forming said coatings into said injection zone of the convergent/divergent nozzle; wherein the convergent/divergent nozzle has a nozzle throat downstream of the injection zone whereby in operation the injection pressure of the feedstock material upstream of the nozzle throat approximates the pressure of the combustion stream within the injection zone. The apparatus may also include the use of an accelerating gas.

A nozzle ejecting liquid and nozzle device ejecting a liquid upon mixing an abrasive into a liquid jet stream, obtains a converged jet stream. A nozzle includes: a main body; a buffer chamber in the body, whose central axis is an axis line being the liquid jet stream central line; a constrictor part ejecting the liquid, in a buffer chamber plane on a buffer chamber front side and whose central axis is the axis line; a disk plate inside the buffer chamber, facing the plane on the buffer chamber front side and whose central axis is the axis line; a supporting member supporting the disk plate within the buffer chamber; a supply opening in the body supplying the liquid; and an inflow channel along a direction different from the axis line extending direction, opened on a disk plate rear side and the buffer chamber and communicating with the opening.

An article may include a substrate including a ceramic matrix composite (CMC); a composite coating layer including a first coating material that includes a rare-earth disilicate and a second coating material that includes at least one of a rare-earth monosilicate, a CMAS-resistant material, or a high-temperature dislocating material, where the second coating material forms a substantially continuous phase in the composite coating layer.