Patent application number | Description | Published |
20090038935 | THERMAL BARRIER COATING RESISTANT TO PENETRATION BY ENVIRONMENTAL CONTAMINANTS - A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment. | 02-12-2009 |
20090142221 | ENGINE COMPONENTS AND METHODS OF FORMING ENGINE COMPONENTS - Engine components that include a compacted powder material comprising a nickel-based superalloy having less than five parts per million sulfur, by weight and methods of forming the components are provided. In an embodiment, by way of example only, a method includes flowing a gas into a can with a metal powder therein, the gas comprising hydrogen, the can configured to be used for a consolidation process, and the superalloy comprising sulfur. Gas is flowed into and then removed from the can. A sulfur content of the removed gas is determined during the process. The can and the metal powder therein are subjected to the consolidation process, if a determination is made that the sulfur content of the metal powder is below a threshold value, the threshold value being a value below about 1 part per million by weight. | 06-04-2009 |
20090317547 | CHEMICAL VAPOR DEPOSITION SYSTEMS AND METHODS FOR COATING A SUBSTRATE - Chemical vapor deposition systems and methods of coating a substrate are provided. The method includes evacuating a processing chamber to a threshold pressure. The substrate and the processing chamber are heated to a first processing temperature. A first pellet having a vaporization temperature that is below the first processing temperature is dispensed into the processing chamber and exposed to the first processing temperature within the processing chamber to vaporize the first pellet into a first processing vapor to produce a pressure change from the threshold pressure to a first pressure to cause the first processing vapor to flow through the processing chamber and onto the substrate. The substrate is exposed to the first processing vapor for a predetermined time. | 12-24-2009 |
Patent application number | Description | Published |
20080219853 | Multi-alloy turbine rotors and methods of manufacturing the rotors - A dual alloy turbine rotor is provided and includes an integrally formed blade ring and a disk. The blade ring is made of a first alloy and includes a ring portion and a plurality of airfoils extending therefrom, where the ring portion includes an inner surface, and each airfoil includes an internal cavity formed therein. The disk is made of a second alloy and may have a beveled outer peripheral surface. The disk is disposed within the ring portion such that the disk outer peripheral surface contacts at least a portion of the ring portion inner surface. Methods of manufacturing the turbine rotor are also provided. | 09-11-2008 |
20080286108 | COLD SPRAYING METHOD FOR COATING COMPRESSOR AND TURBINE BLADE TIPS WITH ABRASIVE MATERIALS - A method for coating compressor or turbine blade tips of a bladed disk with abrasive particles includes installing the blades onto a disk, and then cold gas-dynamic spraying the abrasive particles onto the blade tips while the blades are installed in the disk. According to another embodiment, a method for coating compressor and turbine blade tips of a bladed wheel with abrasive particles includes grinding the blade tips to bring the bladed wheel to a predetermined diameter. Then, surfaces of the bladed wheel not requiring coating are masked. After masking the surface not to be coated, the abrasive particles are cold gas-dynamic sprayed onto the blade tips. For both embodiments, an oxidation resistant layer may be cold gas-dynamic sprayed on the blade tips prior to spraying the abrasive particles. | 11-20-2008 |
20090162205 | TURBINE COMPONENTS AND METHODS OF MANUFACTURING TURBINE COMPONENTS - Turbine components are provided. In an embodiment, by way of example, a hub and a ring are included. The hub comprises a first material. The ring is bonded to the hub. The ring comprises a plurality of arc segments forming a ring, each arc segment comprising a second material comprising a single crystal superalloy material having a predetermined primary orientation and a predetermined secondary orientation, each predetermined primary orientation of each arc segment being substantially equal, and each predetermined secondary orientation of each arc segment being substantially equal, each arc segment adjacent another arc segment, and the adjacent arc segments having a predetermined crystallographic mismatch therebetween. Methods of manufacturing are also provided. | 06-25-2009 |
20090297866 | COMPONENTS AND METHODS OF FORMING PROTECTIVE COATING SYSTEMS ON COMPONENTS - Components and methods of forming a protective coating system on the components are provided. In an embodiment, and by way of example only, the component includes a ceramic substrate and a braze layer disposed over the ceramic substrate. The braze layer includes a silicon matrix having a first constituent and a second constituent that is different than the first constituent. The first constituent forms a first intermetallic with a portion of the silicon matrix and the second constituent forms a second intermetallic with another portion of the silicon matrix, wherein the braze layer is formulated to provide a barrier to oxygen diffusion therethrough. | 12-03-2009 |
20100068507 | NANOLAMINATE THERMAL BARRIER COATINGS - An article having a thermal barrier coating includes a superalloy substrate having a columnar grained ceramic coat formed thereon. The ceramic coat includes a nanolaminate region comprising repeating layers of ceramic material with each layer being less than 500 nm in thickness, with dispersions of metal oxide doping material situated between each of the layers. The ceramic coat further includes a non-doped region having a thickness greater than 500 nm adjacent to the nanolaminate region, the non-doped region including one layer or a plurality of adjacent layers of ceramic material without dispersions of metal oxide doping material situated between each of the layers. In one embodiment, and by way of example only, a bond coat is formed between the substrate and the columnar grained ceramic coat. According to another embodiment, the superalloy substrate forms an adherent alumina scale, and no bond coat is necessary. | 03-18-2010 |
20120174750 | ARMOR MATERIALS, BODY ARMOR ARTICLES AND METHODS OF MANUFACTURE - An armor material, body armor articles, and methods of manufacturing the armor material are provided. In an embodiment, by way of example only, the armor material includes a first plate, a second plate, and a powder material. The first plate includes a layer comprising a metallic material. The second plate is spaced apart from the first plate and includes a layer comprising a ceramic material. The powder material is disposed between the first and the second plates, and comprises loose powder including at least one of a plurality of ceramic particles and a plurality of metallic particles. | 07-12-2012 |
20120223127 | COMPONENTS AND METHODS OF FORMING PROTECTIVE COATING SYSTEMS ON COMPONENTS - Components and methods of forming a protective coating system on the components are provided. In an embodiment, and by way of example only, the component includes a ceramic substrate and a braze layer disposed over the ceramic substrate. The braze layer includes a silicon matrix having a first constituent and a second constituent that is different than the first constituent. The first constituent forms a first intermetallic with a portion of the silicon matrix and the second constituent forms a second intermetallic with another portion of the silicon matrix, wherein the braze layer is formulated to provide a barrier to oxygen diffusion therethrough. | 09-06-2012 |
Patent application number | Description | Published |
20100196191 | NICKEL-BASE SUPERALLOYS - Nickel-base superalloys are provided. In an embodiment, a nickel-base superalloy includes a concentration of large radius elements disposed in the gamma phase of the nickel-base superalloy in a range of from about 3.6 to about 6.7, by atomic percent and a concentration of large radius elements disposed in the gamma prime phase of the nickel-base superalloy in a range of from about 4.2 to about 7.0, by atomic percent. The nickel-base superalloy has a density of about 9.0 grams per centimeter | 08-05-2010 |
20100243464 | METHODS OF FORMING COATINGS ON SUBSTRATES - Methods are provided for forming coatings on substrates. In an embodiment, a method includes forming a first metal layer on the substrate, the first metal layer comprising a first precious metal, electrodepositing an active element over the first metal layer to form an active element layer, the active element selected from the group consisting of yttrium, scandium, and a lanthanide series element, applying a second metal layer over the active element layer, the second metal layer consisting essentially of a metal selected from a group consisting of a second precious metal, nickel, and cobalt, heating the substrate including the first metal layer, the active element layer, and the second metal layer to form a diffusion-alloyed layer over the substrate, adding aluminum to the diffusion-alloyed layer, and heating the substrate to diffuse and react the aluminum with the diffusion-alloyed layer to form a modified precious metal aluminide coating on the substrate. | 09-30-2010 |
20110129687 | METHODS OF JOINING A FIRST COMPONENT AND A SECOND COMPONENT TO FORM A BOND JOINT AND ASSEMBLIES HAVING BOND JOINTS - A method is included for joining two components to form a bond joint, where the first component includes a first alloy having a first composition and a first microstructure, and the second component includes a second alloy having a second composition. A sputter material is sputtered onto a bond surface of the first component to form an interlayer, the sputter material of the interlayer having a third composition, the interlayer having an initial microstructure, the initial microstructure is a nanocrystalline microstructure or an amorphous microstructure. The interlayer is contacted with a joint surface of the second component to form an assembly, which is subjected to a first pressure, heated to a first temperature to thereby form the bond joint, and heated to a second temperature to transform the initial microstructure into the first microstructure. The first microstructure is different from the nanocrystalline microstructure and the amorphous microstructure. | 06-02-2011 |
20110135489 | NICKEL-BASED SUPERALLOYS, TURBINE BLADES, AND METHODS OF IMPROVING OR REPAIRING TURBINE ENGINE COMPONENTS - Nickel-based superalloys, turbine blades, and methods of improving or repairing turbine engine components are included. A nickel-based superalloy includes, by weight, about 5% to about 12% cobalt, about 3% to about 10% chromium, about 5.5% to about 6.3% aluminum, about 5% to about 10% tantalum, about 3% to about 10% rhenium, about 2% to about 5% of one or more of elements selected from a group consisting of platinum, ruthenium, palladium, and iridium, about 0.1% to about 1.0% hafnium, about 0.01% to about 0.4% yttrium, about 0.01% to about 0.15% silicon, and a balance of nickel. | 06-09-2011 |
20110135952 | TURBINE COMPONENTS FOR ENGINES AND METHODS OF FABRICATING THE SAME - A method is provided that includes depositing metal powder over a seed crystal having a predetermined primary orientation, scanning an initial pattern into the metal powder to melt or sinter the deposited metal powder, and re-scanning the initial pattern to re-melt the scanned metal powder and form an initial layer having the predetermined primary orientation. The method further includes depositing additional metal powder over the initial layer, scanning an additional pattern into the additional metal powder to melt or sinter at least a portion of the additional metal powder, re-scanning the additional pattern to re-melt a portion of the initial layer and the scanned deposited additional metal powder to form a successive layer having the predetermined primary orientation, and repeating the steps of depositing additional metal powder, scanning the additional pattern, and re-scanning the additional pattern, until a final shape of the component is achieved. | 06-09-2011 |