Patent application number | Description | Published |
20080220172 | Sintering resistant, low conductivity, high stability thermal barrier coating/environmental barrier coating system for a ceramic-matrix composite (CMC) article to improve high temperature capability - In accordance with an embodiment of the invention, a thermal barrier coating (TBC) for inclusion in a thermal barrier coating/environmental barrier coating system (TBC/EBC system) for use on a silicon containing material substrate is provided. The TBC comprises a compound having a primary constituent portion and a stabilizer portion stabilizing said primary constituent. The primary constituent portion of the TBC comprises hafnia present in an amount of at least about 5 mol % of the primary constituent. The stabilizer portion of said thermal barrier coating comprises at least one metal oxide comprised of cations with a +2 or +3 valence present in the amount of about 10 to about 40 mol % of the thermal barrier coating. | 09-11-2008 |
20090047135 | LAYERED CORROSION RESISTANT COATING FOR TURBINE BLADE ENVIRONMENTAL PROTECTION - The present invention is a gas turbine engine turbine blade comprising an airfoil section having at least an exterior surface, a platform section having an exterior surface, an under platform section having an exterior surface, and a dovetail section having an exterior surface. The blade further comprises a corrosion resistant coating on a surface of a turbine blade section selected from the group consisting of the exterior surface of the under platform section, the exterior surface of the dovetail section, and combinations thereof, the corrosion resistant coating comprising a particulate corrosion resistant component comprising from about 5 weight percent to about 100 weight percent corrosion resistant non-alumina particulates having a CTE greater than that of alumina particulates and balance alumina particulates, and a binder component. The present invention also includes methods for making such a gas turbine engine blade. | 02-19-2009 |
20090098394 | STRAIN TOLERANT CORROSION PROTECTING COATING AND TAPE METHOD OF APPLICATION - A corrosion resistant tape coating for gas turbine engine includes a glassy ceramic matrix wherein the glassy matrix is silica-based, and includes corrosion resistant particles selected from refractory particles and non-refractory MCrAlX particles, and combinations thereof. The corrosion resistant particles are substantially uniformly distributed within the matrix, and provide the coating with corrosion resistance. Importantly the coating of the present invention has a coefficient of thermal expansion (CTE) greater than that of alumina at engine operating temperatures. The CTE of the coating is sufficiently close to the substrate material such that the coating does not spall after frequent engine cycling at temperatures above 1200° F. | 04-16-2009 |
20090162209 | TURBINE ENGINE COMPONENTS WITH ENVIRONMENTAL PROTECTION FOR INTERIOR PASSAGES - A gas turbine blade comprises a base metal, a platform, an airfoil extending upwardly from the platform, a shank extending downwardly from the platform. The shank has an exterior wall and an internal passage, and the airfoil has a cooling flow channel inside the airfoil for flowing a cooling flow therethrough. The blade has a first chromide coating contacting the base metal of at least a portion of an interior surface of the shank and interdiffused therewith, wherein the first chromide coating does not have an aluminide coating deposited over it. The blade has a second chromide coating contacting the base metal of at least a portion of an interior surface of the airfoil and interdiffused therewith. A method for preparing a gas turbine blade comprises the steps of applying chromide coatings, sealing the interior passages of the shank and airfoil and applying an aluminide or platinum aluminide coating and an optional ceramic layer on the airfoil. | 06-25-2009 |
20090162670 | METHOD FOR APPLYING CERAMIC COATINGS TO SMOOTH SURFACES BY AIR PLASMA SPRAY TECHNIQUES, AND RELATED ARTICLES - A method for applying a ceramic coating over a substantially smooth protective coating on a metal substrate is disclosed. The method includes the step of air plasma spraying (APS) particles of the ceramic coating at a pre-selected particle velocity of at least about 500 meters per second. The ceramic coating particles have an average particle size no greater than about 50 microns. An article is also described, including a metal substrate; and a substantially smooth protective coating over the substrate, having a roughness (Ra) less than about 200 micro-inches. An adherent ceramic coating is disposed on the substantially smooth protective coating. | 06-25-2009 |
20090169742 | Coated silicon comprising material for protection against environmental corrosion - In accordance with an embodiment of the invention, an article is disclosed. The article comprises a gas turbine engine component substrate comprising a silicon material; and an environmental barrier coating overlying the substrate, wherein the environmental barrier coating comprises cerium oxide, and the cerium oxide reduces formation of silicate glass on the substrate upon exposure to corrodant sulfates. | 07-02-2009 |
20090191347 | TURBINE COMPONENT OTHER THAN AIRFOIL HAVING CERAMIC CORROSION RESISTANT COATING AND METHODS FOR MAKING SAME - An article comprising a turbine component other than an airfoil having a metal substrate and a ceramic corrosion resistant coating overlaying the metal substrate. This coating has a thickness up to about 5 mils (127 microns) and comprises a ceramic metal oxide selected from the group consisting of zirconia, hafnia and mixtures thereof. This coating can be formed by a method comprising the following steps: (a) providing a turbine component other than an airfoil comprising the metal substrate; (b) providing a gel-forming solution comprising a ceramic metal oxide precursor; (c) heating the gel-forming solution to a first preselected temperature for a first preselected time to form a gel; (d) depositing the gel on the metal substrate; and (e) firing the gel at a second preselected temperature above the first preselected temperature to form the ceramic corrosion resistant coating comprising the ceramic metal oxide. This coating can also be formed by alternative methods wherein a ceramic composition comprising the ceramic metal oxide is deposited by physical vapor deposition on the metal substrate to provide a strain-tolerant columnar structure, or is thermal sprayed on the metal substrate. | 07-30-2009 |
20090191353 | TURBINE COMPONENT OTHER THAN AIRFOIL HAVING CERAMIC CORROSION RESISTANT COATING AND METHODS FOR MAKING SAME - An article comprising a turbine component other than an airfoil having a metal substrate and a ceramic corrosion resistant coating overlaying the metal substrate. This coating has a thickness up to about 5 mils (127 microns) and comprises a ceramic metal oxide selected from the group consisting of zirconia, hafnia and mixtures thereof. This coating can be formed by a method comprising the following steps: (a) providing a turbine component other than an airfoil comprising the metal substrate; (b) providing a gel-forming solution comprising a ceramic metal oxide precursor; (c) heating the gel-forming solution to a first preselected temperature for a first preselected time to form a gel; (d) depositing the gel on the metal substrate; and (e) firing the gel at a second preselected temperature above the first preselected temperature to form the ceramic corrosion resistant coating comprising the ceramic metal oxide. This coating can also be formed by alternative methods wherein a ceramic composition comprising the ceramic metal oxide is deposited by physical vapor deposition on the metal substrate to provide a strain-tolerant columnar structure, or is thermal sprayed on the metal substrate. | 07-30-2009 |
20090220684 | PROCESS OF APPLYING A COATING SYSTEM - A coating process for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating process forms a coating system that includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy. | 09-03-2009 |
20090239061 | CERAMIC CORROSION RESISTANT COATING FOR OXIDATION RESISTANCE - A coating system and a method for forming the coating system, the method including coating a surface of a gas turbine engine turbine component having a metallic surface that is outside the combustion gas stream and exposed to cooling air during operation of the engine. A gel-forming solution including a ceramic metal oxide precursor is provided. The gel-forming solution is heated to a first preselected temperature for a first preselected time to form a gel. The gel is then deposited on the metallic surface. Thereafter the gel is fired at a second preselected temperature above the first preselected temperature to form a ceramic corrosion resistant coating comprising a ceramic metal oxide is selected from the group consisting of zirconia, hafnia and combinations thereof. The ceramic corrosion resistant coating having a thickness of up to about 127 microns and remaining adherent at temperatures greater than about 1000° F. | 09-24-2009 |
20100006001 | Particulate Corrosion Resistant Coating Composition - A composition comprising a glass-forming binder component and a particulate corrosion resistant component. The particulate corrosion resistant component comprises corrosion resistant particulates having: a CTE | 01-14-2010 |
20100151125 | SLURRY CHROMIZING PROCESS - Slurry coating process for selectively enriching surface regions of a metal-based substrate, for example, the under-platform regions of a turbine blade, with chromium. The process employs a slurry coating composition containing metallic chromium, optionally metallic aluminum in a lesser amount by weight than chromium, and optionally other constituents. The composition further includes colloidal silica, and may also include one or more additional constituents, though in any event the composition is substantially free of hexavalent chromium and sources thereof. The coating composition is applied to a surface region to form a slurry coating, which is then heated to remove any volatile components of the coating composition and thereafter cause diffusion of chromium from the coating into the surface region to form a chromium-rich diffusion coating. | 06-17-2010 |
20100158680 | CMAS MITIGATION COMPOSITIONS, ENVIRONMENTAL BARRIER COATINGS COMPRISING THE SAME, AND CERAMIC COMPONENTS COMPRISING THE SAME - Calcium magnesium aluminosilicate (CMAS) mitigation compositions selected from rare earth elements, rare earth oxides, zirconia, hafnia partially or fully stabilized with alkaline earth or rare earth elements, zirconia partially or fully stabilized with alkaline earth or rare earth elements, magnesium oxide, cordierite, aluminum phosphate, magnesium silicate, and combinations thereof when the CMAS mitigation composition is included as a separate CMAS mitigation layer in an environmental barrier coating for a high temperature substrate component. | 06-24-2010 |
20100159150 | METHODS FOR MAKING ENVIRONMENTAL BARRIER COATINGS AND CERAMIC COMPONENTS HAVING CMAS MITIGATION CAPABILITY - Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability involving providing a component; applying an environmental barrier coating to the component, the environmental barrier coating having a separate CMAS mitigation layer including a CMAS mitigation composition selected from rare earth elements, rare earth oxides, zirconia, hafnia partially or fully stabilized with alkaline earth or rare earth elements, zirconia partially or fully stabilized with alkaline earth or rare earth elements, magnesium oxide, cordierite, aluminum phosphate, magnesium silicate, and combinations thereof. | 06-24-2010 |
20100159262 | DURABLE THERMAL BARRIER COATING COMPOSITIONS, COATED ARTICLES, AND COATING METHODS - A composition useful as a thermal barrier coating on a superalloy substrate intended for use in hostile thermal environments. The coating comprises zirconia stabilized in a predominately tetragonal phase. The composition includes a ceramic component consisting essentially of zirconia (ZrO2) or a combination of zirconia and hafnia (HfO2) and a stabilizer component comprising, in combination, a first co-stabilizer selected from YbO1.5, HoO1.5, ErO1.5, TmO1.5, LuO1.5, and combinations thereof, and optionally YO1.5, a second co-stabilizer selected from TiO2, PdO2, VO2, GeO2, and combinations thereof, and a third co-stabilizer comprising TaO2.5. The stabilizer component is present in an amount effective to achieve the predominantly tetragonal phase in the coating. | 06-24-2010 |
20100159270 | DURABLE THERMAL BARRIER COATING COMPOSITIONS, COATED ARTICLES, AND COATING METHODS - A composition useful as a thermal barrier coating on a superalloy substrate intended for use in hostile thermal environments. The coating comprises zirconia stabilized in a predominately tetragonal phase. The composition includes a ceramic component consisting essentially of zirconia (ZrO2) or a combination of zirconia and hafnia (HfO2) and a stabilizer component comprising, in combination, a first co-stabilizer selected from YbO1.5, HoO1.5, ErO1.5, TmO1.5, LuO1.5, and combinations thereof, and a second co-stabilizer selected from TiO2, PdO2, VO2, GeO2, and combinations thereof. Optionally, the stabilizer component includes Y2O3. The stabilizer component is present in an amount effective to achieve the predominantly tetragonal phase in the coating. | 06-24-2010 |
20100254822 | Super oxidation and cyclic damage resistant nickel-base superalloy and articles formed therefrom - A nickel-base superalloy composition including (measured in % by weight) from about 6.5 to about 7.5% aluminum, from about 4 to about 8% tantalum, from about 3 to about 10% chromium, from about 2 to about 7% tungsten, from 0 to about 4% molybdenum, from 0 to about 6% rhenium, from 0 to less than about 0.001% niobium, from 0 to about 5% cobalt, from 0 to about 0.2% silicon, from 0 to about 0.06% carbon, optionally, from 0 to about 0.5% titanium, from 0 to about 0.005% boron, from about 0.15 to about 0.7% hafnium, from 0 to about 0.03% of a rare earth addition selected from the group consisting of yttrium, lanthanum, cesium, and combinations thereof, balance nickel and incidental impurities. The nickel-base superalloy composition may be used in single-crystal or directionally solidified superalloy articles such as high pressure turbine blades for a gas turbine engine. | 10-07-2010 |
20100276036 | CARBURIZATION PROCESS FOR STABILIZING NICKEL-BASED SUPERALLOYS - A process by which a nickel-based superalloy substrate prone to deleterious reactions with an aluminum-rich coating can be stabilized by carburization. The process generally entails processing the surface of the substrate to be substantially free of oxides, heating the substrate in a non-oxidizing atmosphere to a carburization temperature, and then contacting the surface of the substrate with a carburization gas mixture comprising a diluted low activity hydrocarbon gas while maintaining the substrate at the carburization temperature. While at the carburization temperature and contacted by the carburization gas, carbon atoms in the carburization gas dissociate therefrom, transfer onto the surface of the substrate, diffuse into the substrate, and react with refractory metals within the substrate to form refractory metal carbides within a carburized region beneath the surface of the substrate. The substrate is then cooled in a non-oxidizing atmosphere to terminate carbide formation. | 11-04-2010 |
20100279018 | CERAMIC CORROSION RESISTANT COATING FOR OXIDATION RESISTANCE - A coating system and a method for forming the coating system, the method including coating a surface of a gas turbine engine turbine component having a metallic surface that is outside the combustion gas stream and exposed to cooling air during operation of the engine. A gel-forming solution including a ceramic metal oxide precursor is provided. The gel-forming solution is heated to a first preselected temperature for a first preselected time to form a gel. The gel is then deposited on the metallic surface. Thereafter the gel is fired at a second preselected temperature above the first preselected temperature to form a ceramic corrosion resistant coating comprising a ceramic metal oxide is selected from the group consisting of zirconia, hafnia and combinations thereof. The ceramic corrosion resistant coating having a thickness of up to about 127 microns and remaining adherent at temperatures greater than about 1000° F. | 11-04-2010 |
20100330295 | METHOD FOR PROVIDING DUCTILE ENVIRONMENTAL COATING HAVING FATIGUE AND CORROSION RESISTANCE - Method includes providing a superalloy substrate such as a turbine disk, a turbine seal, a turbine blade, a turbine nozzle, a turbine shroud, or a turbine frame or case having an under platform or non-gas path region; and providing a predominantly gamma-prime nickel aluminide intermetallic ductile corrosion and oxidation resistant coating disposed on at least a portion of the substrate. The coating comprises from about 15 to about 30 atomic % aluminum, up to about 20 atomic % chromium, optionally, up to about 30 atomic % of at least one platinum group metal, optionally, up to about 4 atomic % of at least one reactive element, and optionally, up to about 15 atomic % of at least one strengthening element, and a balance being essentially nickel or nickel and at least one of cobalt, iron, or cobalt and iron. A coating precursor composition may be applied to the substrate before or after optional plating with one or more platinum group metals. | 12-30-2010 |
20100330393 | DUCTILE ENVIRONMENTAL COATING AND COATED ARTICLE HAVING FATIGUE AND CORROSION RESISTANCE - A ductile corrosion and oxidation resistant coating, being predominately of gamma-prime nickel aluminide intermetallic includes 15-30 atomic % aluminum, up to atomic % chromium, optionally, up to 30 atomic % of a platinum group metal, optionally, up to 4 atomic % of a reactive element, and optionally, up to 15 atomic % of at least one strengthening element, and a balance being essentially nickel or nickel and at least one of cobalt, iron, or cobalt and iron. A coated article includes the ductile corrosion and oxidation resistant coating on a superalloy substrate such as a turbine disk, turbine seal, a turbine blade, a turbine nozzle, a turbine shroud, or a turbine frame or case having an under platform or non-gas path region. | 12-30-2010 |
20110076410 | METHOD FOR MAKING STRAIN TOLERANT CORROSION PROTECTIVE COATING COMPOSITIONS AND COATED ARTICLES - Method comprising providing a coating precursor composition including a corrosion resistant particulate component having an average coefficient of thermal expansion (CTE) greater than alumina at 1200° F. (649° C.) dispersed in a binder matrix, wherein an aspect ratio of at least a portion of the corrosion resistant particulate component is greater than about 2:1, and wherein the binder matrix includes at least one member of the group consisting of a silicon-containing material and a phosphate-containing material; providing the coating precursor composition on at least a portion of a metal substrate, and; curing the coating precursor composition to provide a corrosion-resistant coating on at least the portion of the metal substrate. | 03-31-2011 |
20110076480 | STRAIN TOLERANT CORROSION PROTECTIVE COATING COMPOSITIONS AND COATED ARTICLES - A coated article suitable for use at elevated temperature includes a metal substrate and a coating on the substrate. The coating includes a corrosion resistant particulate component having an average coefficient of thermal expansion (CTE) greater than alumina at 1200° F. (649° C.) dispersed in a binder matrix. An aspect ratio of at least a portion of the corrosion resistant particulate component is greater than about 2:1. The binder matrix includes a silicon-containing material and/or a phosphate-containing material. | 03-31-2011 |
20120060721 | SLURRY CHROMIZING COMPOSITIONS - Slurry coating composition for selectively enriching surface regions of a metal-based substrate, for example, the under-platform regions of a turbine blade, with chromium. The slurry coating composition contains metallic chromium, optionally metallic aluminum in a lesser amount by weight than chromium, and optionally other constituents. The composition further includes colloidal silica, and may also include one or more additional constituents, though in any event the composition is substantially free of hexavalent chromium and sources thereof. The coating composition can be used in a process that entails applying the coating composition to a surface region to form a slurry coating, and then heating the coating to remove any volatile components of the coating composition and thereafter cause diffusion of chromium from the coating into the surface region to form a chromium-rich diffusion coating. | 03-15-2012 |