A steel piston with an engineered coating is provided. A high thermal conductivity material, for example copper, is disposed on first regions of a combustion bowl to reduce hot spots in the piston. A low thermal conductivity material, for example a ceramic, is disposed on second regions of the combustion bowl to reduce loss of heat through the piston. The high thermal conductivity material disposed on the combustion bowl has a surface roughness (R.sub.a) of less than 5 μm to help reflect IR radiation and promote fuel flow. The low thermal conductivity material disposed on the combustion bowl has a surface roughness (R.sub.a) of less than 3 μm to promote fuel flow. The low thermal conductivity material is also disposed on the bowl rim and top ring land, and has a surface roughness (R.sub.a) of greater than 8 μm on the bowl rim and top ring land to retard gas flow.

A method for forming a coating system on a component includes depositing a reactive layer with predetermined CMAS reaction kinetics on at least a portion of a thermal barrier coating. The method also includes activating the reactive layer with a scanning laser. A component, such as a gas turbine engine component, includes a substrate, a thermal barrier coating and a reactive layer. The thermal barrier coating is deposited on at least a portion of the substrate. The reactive layer is deposited on at least a portion of the thermal barrier coating. The reactive layer has predetermined CMAS reaction kinetics activated by laser scanning.

A method for forming a coating system on a component includes depositing a reactive layer with predetermined CMAS reaction kinetics on at least a portion of a thermal barrier coating. The method also includes activating the reactive layer with a scanning laser. A component, such as a gas turbine engine component, includes a substrate, a thermal barrier coating and a reactive layer. The thermal barrier coating is deposited on at least a portion of the substrate. The reactive layer is deposited on at least a portion of the thermal barrier coating. The reactive layer has predetermined CMAS reaction kinetics activated by laser scanning.

A plasma coating an object has an object profile, and includes the steps of: providing a replaceable shield including a jet inlet, a nozzle outlet and a sidewall extending from the jet inlet to the nozzle outlet; detachably attaching the replaceable shield to a jet outlet of a plasma jet generator; placing the object at the nozzle outlet such that the object profile fits closely to the nozzle outlet edge to within a distance of at least 0.1 mm and at most 5 mm; plasma coating the object with a low-temperature, oxygen-free plasma at an operating pressure which is higher than the atmospheric pressure by providing a plasma jet in the shield via the plasma jet generator and injecting coating precursors in the plasma jet in the shield; identifying the provided shield prior to providing the plasma jet.

A method for creating a three-dimensional (3D) mark in a protective coating including at least one of a TBC and a bond coating over a metal part, is provided. The method may include positioning a mask over the protective coating, the mask including an opening pattern therein; and performing an abrasive waterjet process on the protective coating using the mask. The abrasive waterjet erodes a first portion of the protective coating exposed through the first opening pattern to create the 3D mark. The mask is removed, leaving the 3D mark in the protective coating. The 3D mark only partially penetrates through the protective coating. A metal part may include a metal body, a protective coating over the metal body, and the 3D mark in the protective coating, is also provided. The 3D mark in the protective coating may include an opening having a width of between 30 and 300 micrometers.

In one example, a method for forming an environmental barrier coating (EBC) and/or abradable coating on a substrate. The method may include depositing a coating on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited coating, wherein the coating includes at least one of an environmental barrier coating (EBC) and an abradable coating. The method further comprises heat treating the as-deposited coating at or above a first temperature for a first period of time following the deposition of the as-deposited coating on the substrate, wherein heat treating the as-deposited coating includes heating the as-deposited coating to or above the first temperature at a controlled rate. The heat treatment may be configured to at least one of decrease the open pores and/or microcracks of the heat-treated coating compared to the as-deposited coating or control a grain size of the heat-treated coating.

A braking band having an annular band body arranged around a rotation axis and made of one of gray cast iron, steel, aluminum or alloys thereof, has at least one braking surface having an activated band body portion for increasing adhesive capacity of at least one protective surface coating placed on the surface of the activated band body portion and having at least one material with elevated resistance to abrasion. The activated band body portion is arranged on the surface of the annular band body to form an outermost layer of the braking band with the at least one protective surface coating and has a rough profile having at least one channel delimited by at least one pair of projections, extending along a path at least partially surrounding the rotation axis and having a channel bottom and a first channel side forming an acute angle with the channel bottom and an opposite second channel side forming an obtuse angle with the channel bottom.

A method of creating an interface includes: a) adding organometallic compounds to a polymeric material to create an interfacial layer; b) placing the polymeric material having the interfacial layer in a mold; c) heating a deposit material until the deposit material has a predetermined-minimized volumetric density; and d) depositing the deposit material on the interfacial layer. The latent heat of the molten metallic material transfers to the interfacial layer to create chemical bonds and physical interlocks between the interfacial layer and the metallic material. The deposit material cools to form solidified layer on the interfacial layer.

A method of creating an interface includes: a) adding organometallic compounds to a polymeric material to create an interfacial layer; b) placing the polymeric material having the interfacial layer in a mold; c) heating a deposit material until the deposit material has a predetermined-minimized volumetric density; and d) depositing the deposit material on the interfacial layer. The latent heat of the molten metallic material transfers to the interfacial layer to create chemical bonds and physical interlocks between the interfacial layer and the metallic material. The deposit material cools to form solidified layer on the interfacial layer.

The method for obtaining rolling mill rolls with a coating of tungsten carbide or the alloy thereof, wherein the coating is a single layer and is carried out by high velocity thermal spraying is disclosed.