Patent ID: 8486496

Claim:
A deposition method comprising: providing a base material; preparing a powder mixture that includes (a) a metallic component comprising at least one of Al, an Al alloy, and a mixture of Al and an Al alloy and (b) a ceramic component comprising at least one of SiC, Al 2 O 3 , and a mixture of SiC and Al 2 O 3 ; injecting the powder mixture into a spray nozzle; and depositing the powder mixture onto the base material by accelerating the powder mixture in a state of non-fusion at a rate between about 300 m sec −1 and about 1200 m sec −1 via a transportation gas flowing in the spray nozzle; wherein the metallic component is sized to pass through a 200 mesh sieve and the ceramic component has an average particle diameter between about 13 μm and about 35 μm; and wherein the ceramic component comprises at least about 50 vol % of the powder mixture.