Patent ID: 8465602

Claim:
A thermally sprayed coating having an amorphous-nanocrystalline-microcrystalline composition structure, said thermally sprayed coating comprising from about 1 to about 95 volume percent of an amorphous phase, from about 1 to about 80 volume percent of a nanocrystalline phase, and from about 1 to about 90 volume percent of a microcrystalline phase, and wherein said amorphous phase, nanocrystalline phase and microcrystalline phase comprise about 100 volume percent of said thermally sprayed coating, in which (i) the nanocrystalline phase comprises discrete particles, wherein said particles comprise one or more grains having a nanocrystalline structure, and wherein said nanocrystalline structure comprises a grain size of less than about 100 nanometers; and (ii) the microcrystalline phase comprises discrete particles, wherein said particles comprise one or more grains having a microcrystalline structure, and wherein said microcrystalline structure comprises a grain size of from about 100 nanometers to less than about 1000 nanometers, wherein the distance between said nanocrystalline phase particles is no greater than about 0.5 mils, the distance between said microcrystalline phase particles is no greater than about 0.5 mils, and the distance between said nanocrystalline phase particles and said microcrystalline phase particles is no greater than about 0.5 mils.