United Technologies Corporation

Gary Charles Shubert

Paul Henry Zajchowski

Donn Blankenship

William Bogue

David A Rutz

Norman Pietruska

Andrew DeBiccari

John M Robertson

Jeffrey D Haynes

A method and apparatus for microplasma spray coating a portion of a substrate, such as a gas turbine compressor blade, without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects inert gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the compressor blade is coated with the powdered material without having to mask the compressor blade.

Method and apparatus for microplasma spray coating a portion of a compressor blade in a gas turbine engine

A method and apparatus for microplasma spray coating a portion of a turbine vane without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the turbine vane is coated with the powdered material without having to mask the turbine vane.

Method and apparatus for microplasma spray coating a portion of a turbine vane in a gas turbine engine

A microplasma spray coating apparatus includes a microplasma apparatus with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects inert gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector nozzle extends through the anode and injects powdered material into the plasma stream for transfer to the workpiece.

Microplasma spray apparatus and method for coating articles using same

A method and apparatus for repairing a thermal barrier coating on components in gas turbine engines and the like. The apparatus includes a microplasma spray gun having an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. The apparatus includes a nozzle for emitting arc gas into the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered thermal barrier coating material into the plasma gas stream. Defective areas of the thermal barrier coating can be patched on the component without masking the component.

Method and apparatus for repairing thermal barrier coatings

Methods are described for applying abradable material onto a seal backing material to form an abradable seal between rotating and stationary components of turbines using cold spray deposition technology to control the density, porosity and thickness of the sealing layer.

Cold sprayed porous metal seals

Microspray apparatus and methods involve injecting powdered material into a plasma gas stream. The material comprises first and second component powders. The second powder is a majority by the weight of the powdered material. The first powder acts as a melting point depressant. The first and second powders may have similar compositions but with the first powder including a greater quantity of a melting point depressant element.

Deposition apparatus and methods

A repair method of propagating epitaxial crystalline structures is provided. The repair method broadly comprises the steps of providing a substrate to be repaired, placing an additive material as a preformed shape onto an area of the substrate to be repaired, utilizing a heat source to heat an entire volume of the additive material and an area adjacent to the additive material to within 0-100&#xb0; F. of their solidus temperatures, holding at the fusion temperature for a time sufficient to allow grain growth and orientation to occur, and ramping down the heat source at a predetermined controlled rate until solidification is complete.

Repair method for propagating epitaxial crystalline structures by heating to within 0-100&#xb0; f of the solidus

A thermal management process for enabling the restoration of a surface of a metallic detail in the presence of at least one bonding material, comprising preparing at least one damaged area on a metallic detail; disposing at least one thermal management component upon a bonding material or a surface area proximate to the bonding material to which the metallic detail is joined; masking at least the surface area and the bonding material with a masking agent; and dimensionally restoring a surface of the metallic detail disposed on the article at a processing temperature lower than a temperature which would degrade the bonding material, the substrate, or the bondment interface therebetween.

Non-invasive thermal management processes for restorating metallic details bonded to substrates

A portable, hand-held microplasma spray coating apparatus comprises an anode, a cathode and an arc gas emitter disposed in a housing, and a powder feeding system, a cooling system and a power source connected to the apparatus. The powder feeding system, cooling system and power source are detachably mounted on a mobile platform. The microplasma spray apparatus can be transported to on-site locations in the field to facilitate quick repair work.

Growing community of inventors

East Hampton, CT, United States of America

Gary Charles Shubert