An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. A weld bead is applied to at least one of the edges of the diffusion surface alloyed metal sheet for edge protection or to join the edge of the diffusion surface alloyed metal sheet to another diffusion surface alloyed metal sheet. The weld bead includes a high chromium content filler metal to protect the weld bead and the primary metal substrate at the weld joint from corrosion.

An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. A weld bead is applied to at least one of the edges of the diffusion surface alloyed metal sheet for edge protection or to join the edge of the diffusion surface alloyed metal sheet to another diffusion surface alloyed metal sheet. The weld bead includes a high chromium content filler metal to protect the weld bead and the primary metal substrate at the weld joint from corrosion.

Methods for controlled microstructure creation utilize seeding of amorphous layers prior to annealing. Seed crystals are formed on an amorphous layer or layers. The material, size, and spacing of the seed crystals may be varied, and multiple seed layers and/or amorphous layers may be utilized. Thereafter, the resulting assembly is annealed to generate a crystalline microstructure. Via use of these methods, devices having desirable microstructural properties are enabled.

Methods for controlled microstructure creation utilize seeding of amorphous layers prior to annealing. Seed crystals are formed on an amorphous layer or layers. The material, size, and spacing of the seed crystals may be varied, and multiple seed layers and/or amorphous layers may be utilized. Thereafter, the resulting assembly is annealed to generate a crystalline microstructure. Via use of these methods, devices having desirable microstructural properties are enabled.

A method for forming a coating on a surface of an airfoil is provided, where the airfoil has a leading edge, a trailing edge, a pressure side, and a suction side. The method can include forming a platinum-group metal layer on the surface of the airfoil along at least a portion of the trailing edge, and forming an aluminide coating over the surface of the airfoil of the leading edge, the trailing edge, the pressure side, and the suction side. The leading edge may be substantially free from any platinum-group metal. The method may further include, prior to forming the aluminide coating, forming a bond coating on the surface of the airfoil along the leading edge, and after forming the aluminide coating, forming a thermal barrier coating over the bond coating. A method is also generally provided for repairing a coating on a surface of an airfoil.

A method for forming a coating on a surface of an airfoil is provided, where the airfoil has a leading edge, a trailing edge, a pressure side, and a suction side. The method can include forming a platinum-group metal layer on the surface of the airfoil along at least a portion of the trailing edge, and forming an aluminide coating over the surface of the airfoil of the leading edge, the trailing edge, the pressure side, and the suction side. The leading edge may be substantially free from any platinum-group metal. The method may further include, prior to forming the aluminide coating, forming a bond coating on the surface of the airfoil along the leading edge, and after forming the aluminide coating, forming a thermal barrier coating over the bond coating. A method is also generally provided for repairing a coating on a surface of an airfoil.

An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. A weld bead is applied to at least one of the edges of the diffusion surface alloyed metal sheet for edge protection or to join the edge of the diffusion surface alloyed metal sheet to another diffusion surface alloyed metal sheet. The weld bead includes a high chromium content filler metal to protect the weld bead and the primary metal substrate at the weld joint from corrosion.

An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. A weld bead is applied to at least one of the edges of the diffusion surface alloyed metal sheet for edge protection or to join the edge of the diffusion surface alloyed metal sheet to another diffusion surface alloyed metal sheet. The weld bead includes a high chromium content filler metal to protect the weld bead and the primary metal substrate at the weld joint from corrosion.

An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. The primary metal substrate of the diffusion surface alloyed metal sheet is a stainless steel containing at least 10 percent chromium. The secondary metal of the diffusion surface alloyed metal sheet is a metal alloy containing 20 to 35 percent chromium. As a result, the secondary metal of the diffusion surface alloyed metal sheet provides improved corrosion resistance to salt spray and urea.

An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. The primary metal substrate of the diffusion surface alloyed metal sheet is a stainless steel containing at least 10 percent chromium. The secondary metal of the diffusion surface alloyed metal sheet is a metal alloy containing 20 to 35 percent chromium. As a result, the secondary metal of the diffusion surface alloyed metal sheet provides improved corrosion resistance to salt spray and urea.