The invention discloses a two-layered dense metal anticorrosive coating formed by low temperature sintering with an outer layer of an inorganic ceramic coating and an inner layer of a base oxide coating. The raw materials comprise the following components by weight: 50-60 weight percent silicone compound, 20-35 weight percent thermal expansion coefficient adjuster, 3-7 weight percent binder, 5-10 weight percent adhesion adjuster, and 1-4 weight percent catalyst. A preparation process for the two-layered dense metal anticorrosive coating formed by low-temperature sintering comprises the following steps: 1) grinding, 2) wet mixing, 3) drying, 4) grinding, 5) coating, 6) sintering. The coating of this invention has high adhesion, outstanding anti-corrosion resistance, and good durability.

In a first aspect, the present invention relates to a planar sputtering target comprising a target material layer built up by a layering of splats, wherein the target material layer has a layer width and has a microstructure which varies across the layer width. In a second aspect, the present invention relates to a method for manufacturing such a planar sputtering target.

The invention relates to a method of forming a 3-dimensional solid object, comprising the steps: a) cold spraying one or more metallic powder to form a solid three dimensional item; b) thermally sintering the item such that a portion of the sprayed powder liquefies and reduces spaces between, and/or non-adhesion of, one or more solid portions of the item; and c) causing or allowing the portion of the sprayed powder that liquefied on heating, to become solid.

Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.

A method of: forming an aerosol of a powder comprising one or more of lithium, germanium, phosphorus, sulfur, boron, fluorine, chlorine, bromine, aluminum, nitrogen, arsenic, niobium, titanium, vanadium, molybdenum, manganese, zinc, hafnium, and nickel and directing the aerosol at a substrate at a velocity that forms a film of the powder on the substrate. The method makes an article having an ionic conductor in the form of a film at most 0.5 mm thick.

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.

Provided is a nickel-based composite coating, method for producing the same and use thereof. A powder mixture is coated on the surface of a substrate to obtain a nickel-based composite coating, wherein the powder mixture comprises nickel-chromium-boron-silicon powders and barium titanate powders. The barium titanate powders are added to the nickel-based powders as a second phase to form BaTiO.sub.3—NiCrBSi metal-based ceramic composite coating. The nickel-based barium titanate composite coating has an excellent damping shock absorbing performance and gives the substrate strength as well. Comparing with the conventional coating materials, the coating obtained by the present disclosure through plasma cladding technique not only bonds with the substrate in a metallurgic way, but also has a small heat affected zone, specifically, an excellent damping shock absorbing performance. In embodiments of the present disclosure, vibration and noise generated by the cylinder head is reduced 20% by using the shock absorbing cladding coating.

Systems and methods of synthesizing nanoparticles on substrates using rapid, high temperature thermal shock. A method involves depositing micro-sized particles or salt precursors on a substrate, and applying a rapid, high temperature thermal shock to the micro-sized particles or the salt precursors to become nanoparticles on the substrate. A system may include a rotatable member that receives a roll of a substrate sheet having micro-sized particles or salt precursors; a motor that rotates the rotatable member so as to unroll the substrate; and a thermal energy source that applies a short, high temperature thermal shock to the substrate. The nanoparticles may be metallic, ceramic, inorganic, semiconductor, or compound nanoparticles. The substrate may be a carbon-based substrate, a conducting substrate, or a non-conducting substrate. The high temperature thermal shock process may be enabled by electrical Joule heating, microwave heating, thermal radiative heating, plasma heating, or laser heating.

A powder for coating or sintering has a peak assigned to cubic Y.sub.3Al.sub.5O.sub.12 and a peak assigned to orthorhombic YAlO.sub.3 exhibited in X-ray diffractometry, and the intensity ratio of the peak assigned to the (112) plane of the orthorhombic YAlO.sub.3 to the peak assigned to the (420) plane of the cubic Y.sub.3Al.sub.5O.sub.12 is at least 0.01 and less than 1. Alternatively, a powder for coating or sintering includes a composite oxide of yttrium and aluminum, and the volume of pores with a pore size of from 0.1 to 1 μm of the powder is at least 0.16 mL/g. It is preferable that, in X-ray diffractometry using CuKα radiation with a scan range of 2θ=20° to 60°, a peak assigned to the cubic Y.sub.3Al.sub.5O.sub.12 is a peak that shows the highest peak intensity.

A method may include cold spraying a masking material on selected locations of a component to form a masking layer, wherein the masking material comprises a metal or alloy; additively manufacturing an additively manufactured portion of the component at locations at which the masking layer is not present; and removing the masking layer from the component. The masking layer may be configured to protect portions of the component by covering or otherwise providing a physical barrier that reduces or prevents material from adhering to unwanted portions of the component during a subsequent manufacturing and/or repair technique. Additionally, the masking layer may be reflective to infrared radiation and/or intimately contact the component and function as a heat sink or thermally conductive layer to transfer heat from the component.