Recent advances in high velocity oxygen fuel torches in the form of miniaturization, joining, automation, and digitization are increasing the application opportunities for this thermal spray coating technology.

This case study details the noninvasive analysis of an 5000-year-old silver figurine from Iran, now in the collection of The Metropolitan Museum of Art. The The object of this study, a figure of a kneeling bull clothed in a robe with a stepped linear pattern and holding up a spouted vessel, is composed of 15 pieces of worked silver joined together with silver solder. The aim of the study is to apply noninvasive micro-xray fluorescence spectroscopy (μ-XRF) analysis to characterize the silver alloy compositions and compare the new data with previously obtained results from invasive chemical analyses of samples performed by thermal neutron activation.

Developing a disciplined approach to standardizing special processes and introducing new technologies is key to eliminating defects in thermal spray applications.

Innovations built into a new plasma spray torch address shortcomings of previous axial injection equipment.

Automotive die OEMs throughout Europe are using laser heat treatment (LHT) to deliver parts fast, with superior quality, at lower cost. This article presents a basic technical introduction to LHT and the results of a case study of LHT cost savings in automotive trim/form dies.

Triboglide coatings offer enhanced wear resistance in applications like air foil bearings, actuators, and wear components where oil-based lubrication is scarce. They exhibit excellent wear and friction properties compared to other commercially available coatings.

Techniques for the 3D printing of ceramics are evolving beyond product development and prototypes to enable full production-scale operations. This article gives examples of available methods and tradeoffs that must be addressed in developing 3D printing systems for ceramics.

The ability to make components from copper and copper alloys via additive manufacturing is spurring a range of novel applications. Although the high thermal conductivity of copper presents challenges for direct AM processes, fully dense copper components with complex geometries have been demonstrated. Of particular interest is the ability to use AM methods to fabricate internal cooling channels and mesh structures to optimize thermal management. This article describes feasibility studies to evaluate AM processing of copper parts.

Successful part brazing relies on proper joint design, part cleanliness, and correct fixturing of part assemblies. Routine furnace maintenance allows repeatable, quality brazing results over time. This article describes aluminum brazing processes and process control considerations.

Modern society has evolved and progressed in no small part due to the availability of cutting tools made of high-speed steel. This article details advances in tool materials from World War I through the middle of the twentieth century.

This article describes work to develop a cost-efficient plasma gun capable of high deposition rates. Engineers analyzed both gun components and gas flow dynamics to design a gun that improves plasma stability. Considerable effort was spent on characterizing the use of the gun for spraying yttria-stabilized zirconia (YSZ) for thermal barrier applications.

This article considers the effect of atomic oxygen exposure in low earth orbit on thin film solid lubricants of molybdenum disulphide and diamond-like carbon nanocomposites, a silica-containing diamond-like carbon film. Advances in deposition methods over the past few decades enable dense films to be created that are more resistant to oxidative degradation and the effects of adsorbed moisture than their predecessors. Further, incorporating additional phases improves the tribological performance of the films in a range of atmospheres.

Renewed interest in a NASA-developed material known as Triboglide has led to a study of the friction and wear properties of HVOF-sprayed Triboglide coatings and close variants. This article describes the coating process, examines coating cross-sections, and presents and analyzes the results of high-temperature pin-on-disc wear tests.

This article describes the design and operation of a high-deposition rate plasma nozzle developed for ambient pressure spraying.

Active metal brazing played a key role in the development and fabrication of a modified beam target for particle-physics experiments conducted by Fermilab. The new target consists of a titanium tube filled with stacked graphite fins that were bonded in place by means of active metal brazing. This article describes the vacuum process and the methods used to evaluate the brazed titanium-graphite joints.

A high-velocity oxyfuel (HVOF) spray gun that operates on conventional (gas or kerosene) fuels as well as liquid-gas combinations is shown to be capable of producing MCrAlY bond coats consisting of a rough surface layer (for adhesion) on a dense base (for oxidation protection).

This work shows how metallographic analysis combined with energy dispersive X-ray spectroscopy helped investigators determine the basic processing techniques used in a circa 1910 silver-plated brass trombone, specifically, the joint between the mouthpiece receiver and a brace. This entry won the 2011 International Metallographic Contest sponsored by the International Metallographic Society.