Praxair S.t. Technology, Inc.

Praxair Technology, Inc.

Albert Feuerstein

Ann Bolcavage

Thomas Alan Taylor

Danny Lee Appleby

Neil Hitchman

Thomas F Lewis, Iii

Ardy Kleyman

Don J Lemen

David A McPherson

James Munroe

David Sharp

Andrew Thomas Westfall

Scott Cain

Thomas Albert

James Kent Knapp

Kevin E Garing

Zhihong Tang

Christopher A Petorak

Ardy S Kleyman

Thomas F Lewis

James K Knapp

Thomas F Lewis Iii

Novel slurry formulations and processes for forming improved protective coatings used in the hot section components of gas turbine engines are provided. The process includes a unique two-step deposition methodology whereby the required concentration of reactive element within an improved reactive element doped aluminide coating can be consistently produced in a reproducible manner.

Slurry formulations for formation of reactive element-doped aluminide coatings and methods of forming the same

A modular, rotisserie type tooling fixture assembly for use in a coating operation and method of its use are disclosed. The tooling fixture assembly includes an arbor or shaft and a retaining base with a plurality of anchor members disposed in a prescribed radial orientation from the center of the retaining base, the anchor members are uniquely configured or adapted to retain a plurality of workpieces to be coated. The tooling fixture assembly further comprises a unique workpiece masking arrangement that employs a unitary masking cap having a plurality of solid walls or surfaces adapted to cover portions of the plurality of workpieces in a masking relationship.

Tooling fixture assembly for use in a coating operation

A modular, rotisserie type multifunctional tooling fixture assembly is disclosed. The disclosed tooling fixture assembly comprises a positioning ring having a plurality of anchor members configured or adapted to retain a plurality of workpieces to be processed, and a retaining base defining a plurality of retaining members configured to be in locking engagement with the anchor members of the positioning ring and retain a plurality of workpieces in a fixed orientation. The tooling fixture assembly has utility in various coating related processes, including coating and grit blasting operations.

Multifunction tooling fixture assembly for use in a coating related operations

This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of verticalzA macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

High purity powders

This invention relates to thermally sprayed coatings of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

High purity zirconia-based thermally sprayed coatings and processes for the preparation thereof

This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

High purity zirconia-based thermally sprayed coatings

This invention relates to a fixture for use in a physical vapor deposition coating operation which comprises a support structurecomprising a circular base member, a circular top memberopposite the circular base member, and a plurality of structural membersjoining said top memberto said base member; a plurality of panel membersaligned in a vertical direction around the outer periphery of said support structureforming a cylinder structure; said panel membersincluding a plurality of apertures for holding workpiecesandto which a coating is to be applied; and said apertures positioned on said panel membersso that said workpiecesandare aligned in a staggered vertical direction. This invention also relates to a method for simultaneously coating a plurality of workpiecesand, such as gas turbine compressor blades and vanes, with erosion resistant coatings using the fixture of this invention.

Method for simultaneously coating a plurality of workpieces

This invention relates to dense, vertically cracked thermal barrier coatings made from high purity yttria or ytterbia stabilized zirconia powders. The high purity yttria or ytterbia stabilized zirconia powder consisting essentially of less than about 0.01 weight percent silicon dioxide (silica), less than about 0.002 weight percent aluminum oxide (alumina), less than about 0.005 weight percent calcium oxide, less than about 0.005 weight percent ferric oxide, less than about 0 to about 0.002 weight percent magnesium oxide, less than about 0 to about 0.005 weight percent titanium dioxide, from about 1.5 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria), less than 0.1 weight percent other impurity oxides, and the balance zirconium oxide (zirconia) and the balance zirconium oxide (zirconia). The thermal barrier coatings are intended to be used in cyclic thermal environments such as for gas turbine blades, vanes and seal surfaces exposed in the hot section of gas turbine engines.

Dense vertically cracked thermal barrier coatings

This invention relates to erosion resistant coatings comprising at least 2 sublayer systems in which each sublayer system is separated from another by an interlayer, wherein (i) each sublayer system is the same or different and comprises at least 4 layers, (ii) said layers comprise alternating layers of a nitride-containing compound of stoichiometric composition and a nitride-containing compound of nonstoichiometric composition, (iii) each sublayer system has a thickness of greater than about 0.4 microns, and (iv) each interlayer is the same or different and comprises a metal-containing compound. This invention also relates to a method for producing the coatings and to articles, e.g., gas turbine compressor rotor blade and stator vanes, coated with the coatings.

Multilayer nitride-containing coatings

This invention relates to articles coated with a thermally sprayed coating of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). The articles include, for example, blades, vanes and seal surfaces of gas turbine engines coated with a thermal barrier coating.

Coated articles

This invention relates to a fixture for use in a physical vapor deposition coating operation which comprises a support structurecomprising a circular base member, a circular top memberopposite the circular base member, and a plurality of structural membersjoining said top memberto said base member; a plurality of panel membersaligned in a vertical direction around the outer periphery of said support structureforming a cylinder-like structure; said panel membersincluding a plurality of apertures for holding workpiecesandto which a coating is to be applied; and said apertures positioned on said panel membersso that said workpiecesandare aligned in a staggered vertical direction. This invention also relates to a method for simultaneously coating a plurality of workpiecesand, such as gas turbine compressor blades and vanes, with erosion resistant coatings using the fixture of this invention.

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Carmel, IN, United States of America

Albert Feuerstein