Sulzer Metco (us) Inc.

Sulzer Metco Venture LLC

Jacobus Cornelis Doesburg

Richard Karl Schmid

Liangde Xie

Mitchell R Dorfman

Matthew Gold

Thomas H Piquette

David S Gollob

Omar Basil Al-Sabouni

James Derby

Omar Sabouni

A method for forming a ceramic containing composite structure is proposed comprising the steps of (a) feeding a ceramic component that sublimes and a metallic or semi-conductor material that does not sublime into a thermal spray apparatus, (b) spraying the ceramic component and the metallic or semi-conductor material onto a substrate, whereby the ceramic component and the metallic or semi-conductor material deposit on the surface of the substrate, and (c) keeping the metallic or semi-conductor material on the substrate surface plastic during spraying at least in the region where the metallic or semi-conductor material actually strikes the surface.

Method for forming ceramic containing composite structure

The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.

High purity ceramic abradable coatings

The invention is directed to high purity zirconia-based and/or hafnia-based materials and coatings for high temperature cycling applications. Thermal barrier coatings made from the invention high purity material was found to have significantly improved sintering resistance relative to coatings made from current materials of lower purity. The invention materials are high purity zirconia and/or hafnia partially or fully stabilized by one or any combinations of the following stabilizers: yttria, ytterbia, scandia, lanthanide oxide and actinide oxide. Limits for impurity oxide, oxides other than the intended ingredients, that lead to significantly improved sintering resistance were discovered. High purity coating structures suitable for high temperature cycling applications and for application onto a substrate were provided. In one structure, the coating comprises a ceramic matrix, porosity and micro cracks. In another structure, the coating comprises a ceramic matrix, porosity, macro cracks and micro cracks. In another structure, the coating comprises ceramic columns and gaps between the columns. In another structure, the coating comprises ceramic columns, gaps between the columns and nodules distributing randomly in the gaps and columns.

Optimized high temperature thermal barrier

A mechanical seal structure and a method for manufacture that employs at least one ceramic seal face prepared by a thermal spray process.

Mechanical seals and method of manufacture

The invention relates to a thermal spray feedstock composition that employs free flowing agglomerates formed from (a) a ceramic component that sublimes,(b) a metallic or semi-conductor material that does not sublime and (c) a binder. The invention also relates to a method for preparing the agglomerates and a method for preparing ceramic containing composite structures from the agglomerates.

Thermal spray feedstock composition

The invention is directed to a ceramic material for use in thermal barriers for high temperature cycling applications and high temperature abradable coatings. The material is an alloy formed predominantly from ultra-pure zirconia (ZrO) and/or hafnia (HfO) that has uncharacteristically high sintering resistance to achieve a high service lifetime and low thermal conductivity to achieve high operating temperatures. In the material, oxide impurities such as soda (NaO), silica (SiO), alumina (AlO), titania (TiO), hematite (FeO), calcia (CaO), and magnesia (MgO) make up no more than 0.15 weight percent. The invention provides materials to produce a coating structure so that the changes in the coating microstructure over the in-service lifetime are either limited or beneficial.

Growing community of inventors

Edmonton, Canada

Jacobus Cornelis Doesburg