General Electric Company

Eklavya Calla

Surinder Singh Pabla

Krishnamurthy Anand

Yuk-Chiu Lau

Raymond Henry Goetze

Viswanathan Venkatachalapathy

Marshall Gordon Jones

Ronald Ralph Cairo

Mohamed Rahmane

Pazhayannur Ramanathan Subramanian

David Vincent Bucci

Mohandas Nayak

Sundeep Kumar

Joshua Lee Margolies

Paul Mathew

Gopi Chandran Ramachandran

Guruprasad Sundararajan

Biju Dasan

Shalini Thimmegowda

Padmaja Parakala

Sathisha Chikkabikkodu Hanum

Joydeep Pal

Sanjay Kumar Sondhi

Ramkumar Kashyap Oruganti

Priyanka Saxena

Anantharaman Mahalingam

Prabhakaran Manogharan

Ritwik Biswas

Prazhayannur Ramanathan Subramanian

Ramkumar Oruganti

Various embodiments include a dense abradable coating, a method of reducing rub damage to a turbine engine part by applying the dense abradable coating thereto, and a turbine engine part having the abradable coating thereon. Particular embodiments include a dense abradable coating including a pore-free metallic composite, a high-aluminum containing brittle alloy, and a plurality of hollow abradable particles.

Dense abradable coating with brittle and abradable components

A system for coating a component is provided. The system includes a feedstock supply, a carrier fluid supply, and a thermal spray gun coupled in flow communication with the feedstock supply and the carrier fluid supply. The feedstock supply contains a substantially homogeneous powder mixture of a first powder and a second powder. The second powder is softer than the first powder and has a percentage by mass of the powder mixture of between about 0.1% and about 3.0%.

Feedstocks for use in coating components

A method for repairing a Ni-based alloy component includes preparing a surface of the Ni-based alloy component for receiving a cold spray repair; spraying a stream of particles onto a the surface of the Ni-based alloy component to form a coating thereon; and removing any over-spray on the surface of the Ni-based alloy component. The particles are formed from an alloy material having a melting point such that the particles are sprayed at a spray temperature that is less than the melting point of the alloy material.

Method for repairing turbine component by application of thick cold spray coating

A composition for a reinforced metal matrix coating, and a method of preparing and coating the composition. The composition includes a plurality of sacrificial metallic binder particles that is anodic with respect to a base substrate, and a plurality of hard particles.

Turbine blade coating composition

A method for joining a ceramic component to a metallic component is described. At least one initial layer of an active metal is applied to one of the joining surfaces, by a cold spray technique. At least one second layer of a nickel-based braze composition is then applied over the initial layer by cold-spraying. The braze composition and components are then heated, so as to form an active braze joint between them. A method of sealing an open region of a sodium metal halide-based battery is also disclosed, using the brazing technique described herein to form braze joints that seal various components in the battery cells, such as metallic rings and ceramic collar structures.

Methods for joining ceramic and metallic structures

A process of fabricating a thermal barrier coating is disclosed. The process includes cold spraying a substrate with a feedstock to form a thermal barrier coating and concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating. The cold spraying is in a region having an oxygen concentration of at least 10%. In another embodiment, the process includes heating a feedstock with a laser and cold spraying a substrate with the feedstock to form a thermal barrier coating. At least a portion of the feedstock is retained in the thermal barrier coating. In another embodiment, the process of fabricating a thermal barrier coating includes heating a substrate with a laser and cold spraying the substrate with a feedstock to form a thermal barrier coating.

Process of fabricating thermal barrier coatings

A method of repairing a damaged rotor comprising: (a) preparing a locally damaged portion of the rotor; (b) cold spraying alloy powder particles onto the locally damaged portion; (c) controlling the cold spraying in step (b) to restore the locally damaged portion to form a repaired portion having substantially the same properties and shape as originally manufactured; and (d) heat treating at least the repaired portion.

Method of repairing a turbine rotor using cold spraying

A coating composition, a process of applying a coating having a coating composition, and a process of forming a coating composition are disclosed. The coating composition includes an alloy and an oxide component comprising nickel oxide. The process of applying the coating includes cold spraying the coating onto the article. The process of forming the coating composition includes blending and milling the alloy with the oxide component.

Coating composition, a process of applying a coating, and a process of forming a coating composition

A spray apparatus includes a body having an outer surface and an interior portion, and a first nozzle arranged in the interior portion of the body. The first nozzle includes a first material inlet, a first convergent region, a first throat region, a first divergent region, and a first outlet. The first throat region and first outlet establish a first expansion ratio. A second nozzle is arranged in the interior portion of the body adjacent the first nozzle. The second nozzle includes a second material inlet, a second convergent region, a second throat region, a second divergent region, and a second outlet. The second throat region and the second outlet establish a second expansion ratio that is distinct from the first expansion ratio.

Multi-nozzle spray gun

A method of coating a substrate with cryo-milled, nano-grained particles includes forming a face-centered-cubic gamma matrix comprising nickel, cobalt, chromium, tungsten and molybdenum, adding a dispersion strengthening material to the gamma matrix to form a first mixture, cryo-milling the first mixture to form a second mixture to form a nano-grained structure, and cold spraying the second mixture onto a substrate to form a coating having a nano-grained structure.

Method of coating with cryo-milled nano-grained particles

A method of manufacturing a rotor includes: (a) providing a core shaft; (b) cold spraying alloy powder particles onto the core shaft; (c) controlling the cold spraying to form sections at least of different shape along the core shaft to thereby form a near-net shape rotor; and (d) heat treating the near-net shape rotor to relieve stresses and to form diffusion bonding across interfaces between individual powder particles and the core shaft, and finish-shaping said near-net shape rotor.

Turbine rotor fabrication using cold spraying

A spray coating process and apparatus suitable for depositing coatings on surfaces of components, and particularly surfaces that are difficult to access with conventional cold spraying equipment. The process and apparatus employ a spray gun having a tubular body with a longitudinal axis and an exit at one end thereof. The body has a first portion defining a converging passage, a second portion defining a diverging passage that defines the exit of the body, and a throat portion therebetween that defines a throat between and connecting the converging and diverging passages. The gun is further equipped with at least one gas inlet for introducing a gas upstream of the converging passage, and at least one feedstock inlet for introducing a feedstock at or immediately upstream of the throat.

Apparatus and process for depositing coatings

A cold spray coating system comprising, a cold spray coating gun having a nozzle member operative to emit a stream of gas and granules of a coating material from a nozzle opening defined by the nozzle member such that the granules of the coating material impact and bond with a first region of a substrate, and a heat source member operative heat the first region of the substrate.

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Bengaluru, India

Eklavya Calla