A method is described that can be used in electrodes for electrochemical devices and includes disposing a precious metal on a top surface of a corrosion-resistant metal substrate. The precious metal can be thermally sprayed onto the surface of the corrosion-resistant metal substrate to produce multiple metal splats. The thermal spraying can be based on a salt solution or on a metal particle suspension. A separate bonding process can be used after the metal splats are deposited to enhance the adhesion of the metal splats to the corrosion-resistant metal substrate. The surface area associated with the splats of the precious metal is less than the surface area associated with the top surface of the corrosion-resistant metal substrate. The thermal spraying rate can be controlled to achieve a desired ratio of the surface area of the metal splats to the surface area of the corrosion-resistant metal substrate.

Tunable thermoplastic polymer sealants and tunable conductive thermoplastic polymer sealants, and edge seals and fillet seals produced from such sealants; and substrates, components and objects comprising the tunable edge seals and fillet seals, and methods for making and applying such edge seals and fillet seals are disclosed.

Tunable thermoplastic polymer sealants and tunable conductive thermoplastic polymer sealants, and edge seals and fillet seals produced from such sealants; and substrates, components and objects comprising the tunable edge seals and fillet seals, and methods for making and applying such edge seals and fillet seals are disclosed.

A system may include a suspension delivery assembly; a thermal spray device; and a computing device. The computing device may be configured to control the suspension delivery assembly to deliver a first suspension comprising a first carrier liquid composition and a powder to the thermal spray device, wherein the thermal spray device delivers the first suspension to a substrate to form a first portion of a coating comprising the powder on the substrate; and control the suspension delivery assembly to deliver a second suspension comprising a second carrier liquid composition and the powder to the thermal spray device, wherein the thermal spray device delivers the second suspension to the substrate to form a second portion of the coating comprising the powder on the substrate.

A method for cleaning a surface of a substrate with an atmospheric pressure plasma process in which a plasma is generated at atmospheric pressure. The plasma has an energetic species reactive with one or more components of an undesirable material on the substrate. In this method, the plasma flows from a nozzle exit as a plasma plume exiting into an ambient environment, and the surface of the substrate is exposed to the energetic species in the plasma plume, thereby producing an activated surface capable of adhering on contact a coating material to the activated surface.

A method for cleaning a surface of a substrate with an atmospheric pressure plasma process in which a plasma is generated at atmospheric pressure. The plasma has an energetic species reactive with one or more components of an undesirable material on the substrate. In this method, the plasma flows from a nozzle exit as a plasma plume exiting into an ambient environment, and the surface of the substrate is exposed to the energetic species in the plasma plume, thereby producing an activated surface capable of adhering on contact a coating material to the activated surface.

The present invention relates a coating powder comprising a rare earth oxyfluoride (Ln-O—F) and having: an average particle size (D.sub.50) of 0.1 to 10 μm, a pore volume of pores having a diameter of 10 μm or smaller of 0.1 to 0.5 cm.sup.3/g as measured by mercury intrusion porosimetry, and a ratio of the maximum peak intensity (S0) assigned to a rare earth oxide (Ln.sub.xO.sub.y) in the 2θ angle range of from 20° to 40° to the maximum peak intensity (S1) assigned to the rare earth oxyfluoride (Ln-O—F) in the same range, S0/S1, of 1.0 or smaller in powder X-ray diffractometry using Cu-Kα rays or Cu-Kα.sub.1 rays.

The present invention relates a coating powder comprising a rare earth oxyfluoride (Ln-O—F) and having: an average particle size (D.sub.50) of 0.1 to 10 μm, a pore volume of pores having a diameter of 10 μm or smaller of 0.1 to 0.5 cm.sup.3/g as measured by mercury intrusion porosimetry, and a ratio of the maximum peak intensity (S0) assigned to a rare earth oxide (Ln.sub.xO.sub.y) in the 2θ angle range of from 20° to 40° to the maximum peak intensity (S1) assigned to the rare earth oxyfluoride (Ln-O—F) in the same range, S0/S1, of 1.0 or smaller in powder X-ray diffractometry using Cu-Kα rays or Cu-Kα.sub.1 rays.

The present disclosure relates to an yttrium-based granular powder for thermal spraying. More particularly, the yttrium-based granular powder is a mixture including one or more yttrium compound powders selected from among Y2O3, YOF, YF3, Y4Al2O9, Y3Al5O12, and YAlO3, and a silica (SiO.sub.2) powder. A Y—Si—O intermediate phase is included therein in a content of less than 10 wt %. The thermal spray coating manufactured using the same has a low porosity, and forms a very dense thin film, thus ensuring excellent plasma resistance.

Provided is a thermal spraying material capable of forming a thermally sprayed coating film having improved plasma erosion resistance. The invention disclosed here provides a thermal spraying material. This thermal spraying material comprises composite particles in which a plurality of yttrium fluoride microparticles are integrated. In addition, the compressive strength of the composite particles is 5 MPa or more.