General Electric Company

Brian Thomas Hazel

Bangalore Aswatha Nagaraj

Irene T Spitsberg

Christine Govern

Ramgopal Darolia

Brett Allen Rohrer Boutwell

Michael James Weimer

Mark Daniel Gorman

Brett Allen Boutwell

David John Wortman

David Joseph Mitchell

Ming Fu

Glen Harold Kirby

Curtis Alan Johnson

Andrew Jay Skoog

Jane Ann Murphy

Roger Dale Wustman

Yan Gao

Joseph Aloysius Heaney

Joseph David Rigney

John Frederick Ackerman

Don Mark Lipkin

Douglas Gerard Konitzer

Nripendra Nath Das

Jeffrey Allan Pfaendtner

William Clarke Brooks

Matthew Bernard Buczek

Rudolfo Viguie

Robert George Zimmerman, Jr

Michael Howard Rucker

Bryan Thomas Bojanowski

Eva Zielonka Lanman

Paul John Fink

Nicole Marie Polley

Kathleen Diana Brammer

Christine Walston

Joseph M Greene

Joshua Leigh Miller

Ramgopal Dorolia

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.

CMAS mitigation compositions, environmental barrier coatings comprising the same, and ceramic components comprising the same

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.

Methods for making environmental barrier coatings and ceramic components having CMAS mitigation capability

A method for forming a nickel aluminide based coating on a metallic substrate includes providing a first source for providing a significant portion of the aluminum content for a coating precursor and a separate nickel alloy source for providing substantially all the nickel and additional alloying elements for the coating precursor. Cathodic arc (ion plasma) deposition techniques may be utilized to provide the coating precursor on a metallic substrate. The coating precursor may be provided in discrete layers, or from a co-deposition process. Subsequent processing or heat treatment forms the nickel aluminide based coating from the coating precursor.

Nickel aluminide coating systems and coated articles

Turbine airfoil components with protective layers and methods therefore. The components are each formed to have a platform, an airfoil extending upwardly from the platform, and 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 component has an interior chromide coating contacting at least a portion of an interior surface of the shank and interdiffused with a base metal thereof, and an exterior chromide coating contacting at least a portion of an exterior surface of the shank and interdiffused with the base metal thereof. The interior and exterior chromide coatings do not have an aluminide coating deposited thereon.

Turbine engine components with environmental protection for interior passages

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.

Carburization process for stabilizing nickel-based superalloys

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.

Process of applying a coating system

A corrosion resistant coating system having a first coating and a second coating. The first coating includes a matrix and corrosion resistant particles. The matrix is preferably a matrix material selected from the group consisting of silica, silicone, phosphate, chromate, and combinations thereof. The corrosion resistant particles are uniformly distributed within the matrix and provide the coating a predetermined coefficient of thermal expansion. The particles provide the first coating with corrosion resistance. The second coating is disposed on at least a portion of the first coating. The second coating includes an organic material capable of sufficiently sealing the pores of the first coating to reduce or eliminate infiltration of contaminant material, and is capable of being removed by exposure elevated temperatures.

Strain tolerant coating for environmental protection

A protective coating for use on a silicon-containing substrate, and deposition methods therefor. The coating has a strontium-aluminosilicate (SAS) composition that is less susceptible to degradation by volatilization and in corrosive environments as a result of having at least an outer surface region that consists essentially of one or more stoichiometric crystalline phases of SAS and is substantially free of a nonstoichiometric second crystalline phase of SAS that contains a substoichiometric amount of silica. The coating can be produced by carrying out deposition and heat treatment steps that result in the entire coating or just the outer surface region of the coating consisting essentially of the stoichiometric celsian phase.

Environmental barrier coating for silicon-containing substrates and process therefor

A method for producing a thermal barrier coating/environmental barrier coating system on a silicon containing material substrate includes applying an environmental barrier coating (EBC) over the silicon containing material substrate; and applying a thermal barrier coating (TBC) over the EBC. The thermal barrier coating includes a compound having a primary constituent portion and a stabilizer portion stabilizing said primary constituent. The primary constituent portion of the thermal barrier coating includes hafnia present in an amount of at least about 5 mol % of the primary constituent and the stabilizer portion of said thermal barrier coating includes 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.

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

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 CTEof at least about 4 and being solid at a temperature of about 1300&#xb0; F. (704&#xb0; C.) or greater; and a maximum median particle size defined by one of the following formulas: (a) for a CTEof 8 or less, an MP equal to or less than (4.375&#xd7;CTE)&#x2212;10; and (b) for a CTEp of greater than 8, an Mequal to or less than (&#x2212;4.375&#xd7;CTE)+60, wherein CTEis the average CTE of the corrosion resistant particulates and wherein Mis the median equivalent spherical diameter (ESD), in microns, of the corrosion resistant particulates. Also disclosed is an article comprising a turbine component comprising a metal substrate and a corrosion resistant coating overlaying the metal substrate, as well as a method for forming at least one layer of the corrosion resistant coating adjacent to the metal substrate. The corrosion resistant coating has a maximum thickness defined by one of the following formulas: (3) for a CTEof 8 or less, an Tequal to or less than (1.5&#xd7;CTE)&#x2212;3.5; and (4) for a CTEof greater than 8, an Tequal to or less than (&#x2212;1.5&#xd7;CTE)+20.5, wherein Tis the thickness, in mils, of the corrosion resistant coating.

Particulate corrosion resistant coating composition

A corrosion resistant 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&#xb0; F.

Strain tolerant corrosion protecting coating and spray method of application

A protective coating for use on a silicon-containing substrate, and deposition methods therefor. The coating has a barium-strontium-aluminosilicate (BSAS) composition that is less susceptible to degradation by volatilization and in corrosive environments as a result of having at least an outer surface region that consists essentially of one or more stoichiometric crystalline phases of BSAS and is substantially free of a nonstoichiometric second crystalline phase of BSAS that contains a substoichiometric amount of silica. The coating can be produced by carrying out deposition and heat treatment steps that result in the entire coating or just the outer surface region of the coating consisting essentially of the stoichiometric celsian phase.

According to an embodiment of the invention, an article of manufacture for use in a gas turbine engine is disclosed. The article comprises a part having a surface covered with a ceramic thermal barrier coating. The thermal barrier coating has an outer surface covered with a sacrificial phosphate coating, wherein the sacrificial phosphate coating reacts with contaminant compositions to prevent contaminant infiltration into the thermal barrier coating.

Protection of thermal barrier coating by a sacrificial coating

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 one micrometer and consists of a ceramic composition that comprises a ceramic metal oxide selected from the group consisting of zirconia, hafnia and mixtures thereof. This coating can be formed by alternative methods to have different microstructures, including a dense matrix or a strain-tolerant columnar grain structure.

Turbine component other than airfoil having ceramic corrosion resistant coating and methods for making same

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 CTEof at least about 4 and being solid at a temperature of about 1300&#xb0; F. (704&#xb0; C.) or greater; and a maximum median particle size defined by one of the following formulas: (a) for a CTEof 8 or less, an Mequal to or less than (4.375&#xd7;CTE)&#x2212;10; and (b) for a CTEof greater than 8, an Mequal to or less than (&#x2212;4.375&#xd7;CTE)+60, wherein CTEis the average CTE of the corrosion resistant particulates and wherein Mis the median equivalent spherical diameter (ESD), in microns, of the corrosion resistant particulates. Also disclosed is an article comprising a turbine component comprising a metal substrate and a corrosion resistant coating overlaying the metal substrate, as well as a method for forming at least one layer of the corrosion resistant coating adjacent to the metal substrate. The corrosion resistant coating has a maximum thickness defined by one of the following formulas: (3) for a CTEof 8 or less, an Tequal to or less than (1.5&#xd7;CTE)&#x2212;3.5; and (4) for a CTEof greater than 8, an Tequal to or less than (&#x2212;1.5&#xd7;CTE)+20.5, wherein Tis the thickness, in mils, of the corrosion resistant coating.

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West Chester, OH, United States of America

Brian Thomas Hazel