United Technologies Corporation

Dinesh K Gupta

James Thompson Beals

David A Litton

Michael J Maloney

Walter E Olson

Sudhangshu Bose

Melvin Freling

Nicholas E Ulion

David S Duvall

Brian S Tryon

Benjamin Joseph Zimmerman

Mladen F Trubelja

Mark T Ucasz

Michael S Milaniak

Jeanine T Marcin

Dilip M Shah

Daniel A Bales

Alan David Cetel

Carl R Verner

Keith A Santeler

Stephen Douglas Murray

Daniel F Paulonis

John J Marcin

Joshua E Persky

Jacob A Snyder

Glenn A Cotnoir

Ken Robert Lagueux

John D Wiedemer

Venkat Seetharaman

David L Lambert

Jeanine D Marcin

Jeanine T DeMasi-Marcin

Stephen D Murray

Keith Santeler

A coated article has: a metallic substrate (); a bondcoat (); and a thermal barrier coating (TBC) (). The bondcoat has a first layer () and a second layer (), the first layer having a lower Cr content than the second layer.

Spallation-resistant thermal barrier coating

A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Refractory metal core coatings

A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Thermal barrier coating system utilizing localized bond coat and article having the same

A gas turbine engine seal system includes a rotating member having an abrasive tip disposed in rub relationship to a stationary, abradable seal surface. The abrasive tip comprises a zirconium oxide abrasive coat having a columnar structure that is harder than the abradable seal surface such that the abrasive tip can cut the abradable seal surface.

Columnar zirconium oxide abrasive coating for a gas turbine engine seal system

In a gas turbine engine, a method and apparatus for containing molten materials and ignited titanium and titanium alloys within the confines of the turbine engine environment. The method includes the step of first applying a bond coating to the inner surface of the outer compressor casing. The bond coating is then plasma oversprayed with a non-reactive, thermally insulative ceramic top coating. The apparatus includes a substrate having a bond coating and a ceramic top coating, surrounding at least a portion of the gas turbine engine, for containing turbine engine fires within the turbine engine environment. Preferably, the bond coating is a Ni--Co--Cr--Al--Y alloy, and the top coat is stabilized zirconia.

Coating scheme to contain molten material during gas turbine engine fires

Blades for use in modern gas turbine engines are described and are characterized by a thin zone of fine grains of a high strength composition on the surface of the blade root.

Turbine engine blade having a zone of fine grains of a high strength

The oxidation resistance of MCrAlY-type overlay coatings is improved by incorporating small discrete oxide particles into the coating. The particles are preferably yttrium oxide, and the coating is applied by simultaneously plasma spraying MCrAlY-type powder particles and oxide particles onto a substrate in a nonoxidizing atmosphere. Improvements in resistance to rumpling has also been observed in coatings applied according to this invention.

Oxide containing MCrAlY-type overlay coatings

Methods are described for forming an yttrium enriched aluminide coating on the surface of a nickel or cobalt base superalloy article. In one preferred embodiment, a pack mixture for forming the coating consists essentially of, by weight percent, 5-35 of an Al-Y-Si alloy, 1-20 CoI.sub.2, balance Y.sub.2 O.sub.3.

Powder mixture for making yttrium enriched aluminide coatings

A protective coating system for superalloys is described. The coating is an active element enriched aluminide, and can be formed by aluminizing an overlay coated superalloy, wherein during the aluminizing process, aluminum diffuses completely through the overlay coating and into the substrate. The coating system exhibits desirable oxidation resistance and resistance to thermal fatigue cracking, due to the presence of oxygen active elements in the overlay.

Aluminide coating for superalloys

A protective coating system for superalloys is described. The coating is an yttrium enriched aluminide, and can be formed by aluminizing an MCrAlY coated superalloy, wherein during the aluminizing process, aluminum diffuses completely through the MCrAlY coating and into the substrate. The coating system exhibits desirable oxidation resistance and resistance to thermal fatigue cracking.

Yttrium enriched aluminide coating for superalloys

Coated gas turbine engine hardware is described. The hardware comprises a titanium alloy substrate having a coating thereon consisting essentially of titanium nitride wherein the ratio of nitrogen to titanium is greater than one. Such coatings have a residual compressive stress state which aids in minimizing the fatigue debit which would otherwise result from the use of a hard coating on a titanium substrate. Coatings are applied by the use of a vacuum arc deposition process.

Coated gas turbine engine compressor components

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South Windsor, CT, United States of America

Dinesh K Gupta