General Electric Company

Other

Hongyu Wang

Krishan Lal Luthra

Irene T Spitsberg

Kang Neung Lee

Peter Joel Meschter

William Patrick Allen

James L Smialek

Harry Edwin Eaton, Jr

Nathan S Jacobson

Elizabeth J Opila

Bangalore Aswatha Nagaraj

Yuk-Chiu Lau

David Joseph Mitchell

Arnold Thomas Henry

Robert A Miller

Raymond William Heidorn

James Anthony Ruud

Larry Steven Rosenzweig

Narottam P Bansal

Roger Lee Ken Matsumoto

Dennis James Landini

James M Ahrens

Troy Frederick Brenner

Ruth Hughes

Nanottam P Bansal

John A Hornor

Daniel Domanski

A method for manufacturing an article for use in a high-temperature environment, and an article for use in such an environment, are presented. The method comprises providing a substrate; selecting a desired vertical crack density for a protective coating to be deposited on the substrate; providing a powder, wherein the powder has a size range selected to provide a coating having the desired vertical crack density; and applying a thermal-sprayed coating to the substrate, the coating having the desired vertical crack density, wherein the powder is used as a raw material for the coating.

Method for manufacturing articles for high temperature use, and articles made therewith

A method and apparatus for filling preforms with resin or slurry includes a tank for holding the slurry and an autoclave for holding the preforms. The tank and autoclave have a common vacuum system connected thereto, and the tank is disposed above the autoclave. This arrangement provides a compact casting system which utilizes a vacuum and gravity to transfer slurry from the tank to the preforms within the autoclave.

Integrated apparatus and method for filling porous composite preforms

A process of depositing a coating system suitable for use as an environmental barrier coating on various substrate materials, particularly those containing silicon and intended for high temperature applications such as the hostile thermal environment of a gas turbine engine. The process comprises depositing a first coating layer containing mullite, and preferably a second coating layer of an alkaline earth aluminosilicate, such as barium-strontium-aluminosilicate (BSAS), by thermal spraying while maintaining the substrate at a temperature of 800&deg; C. or less, preferably 500&deg; C. or less, by which a substantially crack-free coating system is produced with desirable mechanical integrity.

Method of depositing a coating on Si-based ceramic composites

A process for depositing a ceramic coating system for Si-containing materials, particularly those for articles exposed to high temperatures. The process is particularly applicable to depositing a compositionally-graded coating system comprising multiple ceramic layers with differing compositions, including a dense, strain-tolerant, vertically-cracked YSZ-containing ceramic layer deposited on a ceramic layer having a composition that is a mixture of YSZ and either mullite or BSAS. The process entails depositing the YSZ-containing ceramic layer using a plasma spraying technique while maintaining the substrate at a temperature so as not to form horizontal cracks in the coating system, but still maintain the dense vertically-cracked structure of the YSZ-containing ceramic layer for strain tolerance.

Method of depositing a compositionally-graded coating system

A method of forming an article. The method comprises forming a silicon-based substrate that is oxidizable by reaction with an oxidant to form at least one gaseous product and applying an intermediate layer/coating onto the substrate, wherein the intermediate layer/coating is oxidizable to a nongaseous product by reaction with the oxidant in preference to reaction of the silicon-containing substrate with the oxidant.

Method of making a ceramic with preferential oxygen reactive layer

An article includes a silicon-containing substrate and a modified mullite coating. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating. The article can further comprise a thermal barrier coating applied to the modified mullite coating. The modified mullite coating functions as a bond coating between the external environmental/thermal barrier coating and the silicon-containing substrate. In a method of forming an article, a silicon-containing substrate is formed and a modified mullite coating is applied. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating.

Coated article and method of making

Improved adhesion of thermal barrier coating systems to nonmetallic substrates using a layer of silica on an underlying nonmetallic substrate that includes a silicon containing material is described. The improved adhesion occurs because the improved thermal barrier system improves the temperature capability of the system by providing a layer adjacent the substrate that has improved thermal performance and that is not subject to deterioration. The application of a silica layer of predetermined thickness adjacent the substrate also forms a diffusion barrier for oxygen while eliminating the need to transform an external layer of the substrate by a pre-oxidation step. This diffusion barrier prevents any oxidizable component of the substrate from decomposing. The thermal/environmental barrier coating (T/EBC) system includes an intermediate layer containing YSZ and BSAS, mullite and/or alumina, which is preferably used in combination with a mullite layer that overlies the surface of the silica layer, a layer of BSAS between the mullite layer and the intermediate layer, and a thermal barrier coating of YSZ overlying the intermediate layer.

Environmental/thermal barrier coating system with silica diffusion barrier layer

A coating system having a low thermal conductivity, and a method by which the low thermal conductivity of the coating system is maintained through the development of cracks within a thermal-insulating layer of the coating system. The thermal-insulating layer is a mixture of two or more materials with different coefficients of thermal expansion (CTE). The materials of the thermal-insulating layer are selected and combined so that a low thermal conductivity is maintained for the coating system as the result of cracks developing and propagating from interfaces between the materials when the coating system is subjected to heating and cooling cycles.

Low thermal conductivity thermal barrier coating system and method therefor

A coating composition produces a protective coating to a substrate, which coating has an improved surface smoothness. The coating composition comprises a mixture of at least a first type of particles and a second type of particles that are dispersed in a liquid medium. The particles form a total population of particles having a median ESD in a range from about 1 to about 7 micrometers. The different types of particles have different median ESDs. The first type of particles has a maximum ESD of about 40 micrometers, and the second type of particles has a maximum ESD of about 20 micrometers. A method for producing a coating having an improved surface smoothness comprises applying such a coating composition on a substrate and curing the coating composition to produce a protective coating. The coating may be further densified by a burnishing process or further improved by applying another coating comprising particles having ESDs less than about 4 micrometers.

Compositions and methods for producing coatings with improved surface smoothness and articles having such coatings

An article comprises a silicon-containing substrate and a zircon coating. The article can comprise a silicon carbide/silicon (SiC/Si) substrate, a zircon (ZrSiO ) intermediate coating and an external environmental/thermal barrier coating.

Ceramic with zircon coating

A coating system for Si-containing material, such as those used to form articles exposed to high temperatures, including the hostile thermal environment of a gas turbine engine. The coating system is a compositionally-graded thermal/environmental barrier coating (T/EBC) system that exhibits improved mechanical integrity for high application temperatures that necessitate thick protective coatings. The T/EBC system includes an intermediate layer containing YSZ and BSAS, mullite and/or alumina, which is preferably used in combination with a mullite-containing layer that overlies the surface of the Si-containing material, a layer of BSAS between the mullite-containing layer and the intermediate layer, and a thermal-insulating top coat of YSZ overlying the intermediate layer.

Thermal/environmental barrier coating for silicon-containing materials

A barrier layer for a silicon containing substrate which inhibits the formation of gaseous species of silicon when exposed to a high temperature aqueous environment comprises a barium-strontium alumino silicate.

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Niskayuna, NY, United States of America

Hongyu Wang