United Technologies Corporation

Norton Company

George E Foster

Daniel R Godin

David M Nissley

Harold D Harter

Philip H McCluskey

Charles A Ellis

Stephen Chin

Glenn A Cotnoir

H David Harter

Harry E Eaton

Randall Richard Good

Harry Edwin Eaton, Jr

John Hay

Leonard I Smith

Coatings containing at least 85% by volume crystalline mullite with less than 15% by volume of amorphous material and mullite dissociation phases are plasma sprayed onto the surface of a silicon based ceramic substrate by closely controlling the plasma spray parameters including the mullite feed stock and its particle size, the nozzle outlet stand-off distance, movement of the substrate past the plasma flow, back side heating of the substrate and the powder feed rate through the plasma spray gun.

Plasma sprayed mullite coatings on silicon based ceramic materials

An air seal is illustrated as used in a gas turbine engine. The seal includes at least a seal substrate, a relatively dense, erosion resistant ceramic layer applied over the bond coat, and an abradable ceramic layer applied in a local area over the dense ceramic layer. The abradable ceramic interacts with a component moving relative to the seal, such as a turbine blade that moves relative to the seal, and cooperates with the moving component to provide sealing and thermal insulation.

Article having durable ceramic coating with localized abradable portion

A segmented abradable ceramic coating system having superior abradability and erosion resistance is disclosed. The system includes a duct segment having a metallic substrate, a MCrAlY bond coat on the substrate and a segmented abradable ceramic coating on the bond coat. The segmented abradable ceramic coating includes a base coat foundation layer, a graded interlayer and an abradable top layer for an overall thickness of preferably about 50 mils (1.270 mm). The coating is characterized by a plurality of vertical microcracks. By precisely controlling the deposition parameters, composition of the layers and layer particle morphology, segmentation is achieved, as well as superior abradability and erosion resistance.

Segmented abradable ceramic coating

A gas turbine engine component coating having superior abradability and erosion resistance is disclosed. The coating includes a base coat foundation layer, a graded interlayer and an abradable top layer for an overall thickness of preferably about 50 mils. The coating is characterized by a plurality of vertical microcracks. By precisely controlling the deposition parameters, composition of the layers and layer particle morphology, segmentation is achieved, as well as superior abradability and erosion resistance.

Gas turbine engine component

A method of producing a segmented abradable ceramic coating system having superior abradability and erosion resistance is disclosed. The system includes a duct segment having a metallic substrate, a MCrAlY bond coat on the substrate and a segmented abradable ceramic coating on the bond coat. The segmented abradable ceramic coating includes a base coat foundation layer, a graded interlayer and an abradable top layer for an overall thickness of preferably about 50 mils (1.270 mm). The coating is characterized by a plurality of vertical microcracks. By precisely controlling the deposition parameters, composition of the layers and layer particle morphology, segmentation is achieved, as well as superior abradability and erosion resistance.

Method of producing a segmented abradable ceramic coating system

A method for making grinding wheels having an annular grinding section mounted on a central hub in which a slurry of abrasive particles and ceramic bond is coated on a pre-formed core, shaped, and fired. Method has particular advantage in formation of wide wheels and contoured wheels. Premium abrasive may be employed in the wheels.

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Dudley, MA, United States of America

George E Foster