Honeywell International Inc.

Alliedsignal Inc.

Allied Corporation

Other

Electric Power Research Institute Incorporated

Derek Raybould

Thomas E Strangman

Paul Chipko

Santosh K Das

Chin-Fong Chang

Chien-Wei Li

Bjoern Schenk

Matthew J Pohlman

Murali N Madhava

Margaret M Floyd

Paul J Mravcak

Christian Delacruz

William E Fischer

James Piascik

Malak Fouad Malak

Jerry C LaSalle

Richard L Bye, Jr

Liang A Xue

Vincent Chung

Lee Poandl

George Reimer

Alex Kozlov

Nicholas J DeCristofaro

Paul S Gilman

Devlin M Gualtieri

Michael S Zedalis

Gordon Edward Fish

Howard Horst Liebermann

Joseph Denk

Bradley Reed Tucker

Yiping Hu

Milton Ortiz

Federico Renteria

Alexander S Kozlov

Timothy R Duffy

Siu-Ching D Lui

Edward V Limoncelli

David F Teller

Dulari L Sawhney

Paul A Chipko

Chin Fong Chang

Anthony J Esposito

Svetlana Kozlova, Legal Representative

Carl Kiser

Huu-Duc Trinh-Le

Christian c/o Honeywell Internat Inc Delacruz

Methods for producing a high temperature oxidation and hot corrosion resistant MCrAlX coating on a superalloy substrate include applying an M-metal, chromium, and aluminum or an aluminum alloy comprising a reactive element to at least one surface of the superalloy component by electroplating at electroplating conditions below 100&#xb0; C. in a plating bath thereby forming a plated component and heat treating the plated component.

Methods for producing a high temperature oxidation resistant MCrAlX coating on superalloy substrates

A coating for spark plugs and engine parts is resistant to fouling. The coating may be applied to the spark plug or engine part by dipping the part in a sol gel solution, ensuring it wets the part, and extracting it at a slow, controlled rate. As the part is allowed to dry, the sol gel reacts with moisture in the air to form a thin oxide film. Unlike conventional sol gel applications, which apply the oxide directly to the part, the present invention may form an oxide coating, in situ, while drying in place on the part.

Fouling resistant system

Exemplary embodiments of the invention provide barrier coated substrates and methods of coating a substrate with a barrier coating derived from sol gels. An example includes a barrier coated aerospace component that is subject to hot salt corrosion during use. The barrier coating is derived from oxidation of a coating composition that includes at least one sol gel. The barrier coating resists hot salt corrosion for an incubation period of such duration that an uncoated superalloy substrate under the same conditions would suffer corrosion to a depth of about 2.0 mils. Methods of applying the barrier coating include the steps of selecting a first liquid sol gel and wetting surfaces of the superalloy substrate with the selected first liquid sol gel. The wetted surfaces of the superalloy substrate are subjected to heat treatment. The heat treatment includes sintering of sol gel to oxide to produce a barrier coating.

Protective barrier coatings

A coated component is provided comprising a silicon-based substrate and a braze layer overlying the silicon-based substrate. The braze layer comprises silicon, tantalum, and a metal element having substantially the same melt temperature with silicon as tantalum has with silicon. The braze layer further comprises ceramic particles. Protective coatings are also provided.

Protective coatings and coated components comprising the protective coatings

Methods for producing a high temperature oxidation resistant coating on a superalloy component and the coated superalloy component produced thereby are provided. Aluminum or an aluminum alloy is applied to at least one surface of the superalloy component by electroplating in an ionic liquid aluminum plating bath to form a plated component. The plated component is heat treated at a first temperature of about 600&#xb0; C. to about 650&#xb0; C. and then further heat treated at a second temperature of about 700&#xb0; C. to about 1050&#xb0; C. for about 0.50 hours to about two hours or at a second temperature of about 750&#xb0; C. to about 900&#xb0; C. for about 12 to about 20 hours.

Methods for producing a high temperature oxidation resistant coating on superalloy substrates and the coated superalloy substrates thereby produced

Dispersion strengthened aluminum base alloys are shaped into metal parts by high strain rate forging compacts or extruded billets composed thereof. The number of process steps required to produce the forged part are decreased and strength and toughness of the parts are increased. The dispersion strengthened alloy may have the formula Al,Fe,SiX, wherein X is at least one element selected from Mn, V, Cr, Mo, W, Nb, and Ta, 'a' ranges from 2.0 to 7.5 weight-%, 'b' ranges from 0.5 to 3.0 weight-%, &#x201c;c&#x201d; ranges from 0.05 to 3.5 weight-%, and the balance is aluminum plus incidental impurities. Alternatively, the dispersion strengthened alloy may be described by the formula Al,Fe,SiVX, wherein X is at least one element selected from Mn, Mo, W, Cr, Ta, Zr, Ce, Er, Sc, Nd, Yb, and Y, &#x201c;a&#x201d; ranges from 2.0 to 7.5 weight-%, &#x201c;b&#x201d; ranges from 0.5 to 3.0 weight-%, &#x201c;d&#x201d; ranges from 0.05 to 3.5 weight-%, &#x201c;c&#x201d; ranges from 0.02 to 1.50 weight-%, and the balance is aluminum plus incidental impurities. In both cases, the ratio [Fe+X]:Si in the dispersion strengthened alloys is within the range of from about 2:1 to about 5:1.

High strain rate forming of dispersion strengthened aluminum alloys

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.

Thermal barrier coating resistant to penetration by environmental contaminants

Protective coating systems for gas turbine engine applications and methods for fabricating such protective coating systems are provided. An exemplary method of fabricating a protective coating system on a substrate comprises forming a bond coating on the substrate, forming a silicate layer on the bond coating, forming a thermal barrier coating overlying the silicate layer, and heating the thermal barrier coating.

Protective coating systems for gas turbine engine applications and methods for fabricating the same

According to a method for forming a coating system on a turbine engine component substrate that comprises a nickel-based superalloy substrate having at least one refractory metal included therein, a nickel-based layer is formed on the substrate, the nickel-based layer comprising at least one active material selected from the group consisting of elemental silicon and a silicon compound. The at least one active material is then diffused into the substrate. An yttrium-modified platinum aluminide bond coating, or a MCrAlX bond coating, may be then formed over the active material-modified nickel-based layer.

Method of forming bond coating for a thermal barrier coating

A catalyst system for removing one or more components from a fluid stream includes a binder layer and a plurality of catalyst structures affixed to, and protruding from, the binder layer such that the catalyst structure surface is directly exposed to the fluid stream. Methods for preparing a catalyst system, and for selectively removing components from a fluid stream via a catalyst system are also disclosed.

Low cost quick response catalyst system

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.

Nanolaminate thermal barrier coatings

A protective coating for a component comprising a ceramic based substrate, and methods for protecting the component, the protective coating adapted for withstanding repeated thermal cycling. The substrate may comprise silicon nitride or silicon carbide, and the protective coating may comprise at least one tantalate of scandium, yttrium, or a rare earth element. The protective coating may further comprise one or more metal oxides. The coating protects the substrate from combustion gases in the high temperature turbine engine environment. The coating may be multi-layered and exhibits strong bonding to Si-based substrate materials and composites.

Protective coating for ceramic components

Platinum containing coatings for corrosion and oxidation protection of a substrate, and platinum electrodeposition methods for coating a substrate. The coating may comprise platinum and at least one supplementary constituent, and the method may involve co-electrodeposition of platinum and the supplementary constituent from a single electrolyte composition. The supplementary constituent may comprise chromium, an oxidation protective reactive element, or an alloy of chromium with a reactive element. Components protected by such coatings are also disclosed.

Platinum aluminide coating and method thereof

A braze material and method of brazing titanium metals. The material may consist of Ti, Ni, Cu Zr, PM and M where PM is a precious metal and M may be Fe, V, Cr, Co, Mo, Nb, Mn, Si, Sn, Al, B, Gd, Ge or combinations thereof, with the (Cu+PM)/Ni ratio around 0.9. Optionally, a second brazing may be performed to rebraze any braze joint that did not braze successfully. The second brazing material has a lower braze temperature than the first and may consist of a mixture of Ti, Ni, Cu, Zr PM and M with from 1-20 wt % more Zr, PM, M or combinations thereof than the first braze. The braze material may be placed on a base material, in a vacuum furnace, and heated to form a braze joint between the braze and base material. The heating step may occur from about 800-975&#xb0; C. and over 3 to 15 minutes.

Low cost brazes for titanium

Methods and apparatus to make multilayer thermal barrier coatings for superalloy substrates such as turbine blades or vanes are disclosed. The methods produce non-homogeneous, nanometer-size, successive layers and a non-homogeneous interfacial layer without the use of baffles. Methods are also disclosed to use a lower cost metallic source and an oxygen bleed to create alumina or tantalum oxide vapor, to use a tantalum oxide or an alumina ingot and a low pressure inert gas feed to direct the vapor clouds, to use pulsed evaporation from a secondary vapor source to create non-homogeneous multilayer coating on non-rotated substrates, to use an electric bias to direct the vapor clouds, and to use a mechanical system to direct the vapor clouds or move and position the article to be coated in the clouds.

Apparatus to make nanolaminate thermal barrier coatings

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Denville, NJ, United States of America

Derek Raybould