A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. Such a shot chamber is expected to have an improved service life for die casting of corrosive metals and alloys, including hot chamber die casting of aluminum alloys. An improved hot dipping process using stirring in the molten metal bath is also disclosed.

A process for coating a part by chemical vapor diffusion is provided and includes placing a powder mixture in a chamber, immersing the part partially in the powder mixture, and applying a heat treatment to the part. The powder mixture includes a first component and a second component forming a gaseous compound during the heat treatment so as to allow deposition of the second component on the part. The part includes a metal refractory allow and the second component forms a solid diffusion alloy by solid diffusion with a metal species of the refractory metal alloy to generate a coating. The solid diffusion allow generates a passivating oxide layer when subjected to oxidizing conditions.

A part includes a substrate made of a nickel-based superalloy, the substrate having a first average mass fraction of one or more first elements chosen from hafnium, silicon and chromium, the substrate having an open cavity in the part and a cooling channel, the substrate further including a surface layer partially forming the cavity, the surface layer having a second average mass fraction of the first element or first elements which is greater than the first average mass fraction.

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.

A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. Such a shot chamber is expected to have an improved service life for die casting of corrosive metals and alloys, including hot chamber die casting of aluminum alloys. An improved hot dipping process using stirring in the motel metal bath is also disclosed.

A process for coating a part by chemical vapor diffusion is provided and includes placing a powder mixture in a chamber, immersing the part partially in the powder mixture, and applying a heat treatment to the part. The powder mixture includes a first component and a second component forming a gaseous compound during the heat treatment so as to allow deposition of the second component on the part. The part includes a metal refractory allow and the second component forms a solid diffusion alloy by solid diffusion with a metal species of the refractory metal alloy to generate a coating. The solid diffusion allow generates a passivating oxide layer when subjected to oxidizing conditions.

There is described a method of forming an oxidation resistant coating on a cermet comprising tungsten carbide, tungsten boride, or boron carbide and a metallic binder material. The method comprises exposing the cermet to silicon in the presence of an activator to form a mixture, exposing the mixture to an inert gas, and heating the mixture to a temperature T for a time t, thereby forming a coating on the cermet.

There is described a method of forming an oxidation resistant coating on a cermet comprising tungsten carbide, tungsten boride, or boron carbide and a metallic binder material. The method comprises exposing the cermet to silicon in the presence of an activator to form a mixture, exposing the mixture to an inert gas, and heating the mixture to a temperature T for a time t, thereby forming a coating on the cermet.

A method for producing a FeCr alloy comprises: rolling a slab having a chemical composition containing, by mass %, C: 0.020% or less, Si: 0.01% to 1.5%, Mn: 1.0% or less, P: 0.040% or less, S: 0.010% or less, Cr: 16.0% to 30.0%, Al: 2.0% to 6.5%, N: 0.020% or less, and Ni: 0.50% or less, with the balance being Fe and inevitable impurities to obtain a sheet material; subjecting the sheet material to siliconizing treatment by a thermal CVD method to obtain a FeCr alloy having a Si content of more than 1.5 mass % and 10.0 mass % or less and satisfying:
14.0%?Si+1.15?% Al+0.35?% Cr(1)
where % Si, % Al, and % Cr indicate Si, Al, and Cr contents, by mass %, respectively in the chemical composition of the FeCr alloy.

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.