General Electric Company

Jeffrey Allan Pfaendtner

Joseph David Rigney

Ramgopal Darolia

Irene T Spitsberg

Nripendra Nath Das

William Scott Walston

Michael James Weimer

Matthew David Saylor

James Anthony Ruud

Bangalore Aswatha Nagaraj

Dong-Sil Park

Roger Dale Wustman

Brian Harvey Pilsner

John Lewis Lackman

Melvin Robert Jackson

Glen Harold Kirby

Ji-Cheng Zhao

Brian Thomas Hazel

Brett Allen Boutwell

Reed Roeder Corderman

James Dale Steibel

Thomas Edward Mantkowski

Joshua L Miller

Mark Alan Rosenzweig

Raymond William Heidorn

Brett Allen Rohrer Boutwell

Gary Eugene Wheat

Mark Lloyd Miller

Christine Govern

Richard Arthur Nardi, Jr

Thomas Joseph Cartier

Michael Francis Butler

Mary Heppenstall-Butler

William Evan McCormack

Deborah Anne Schorr

Atul Natwerlal Shah

Jessica Lee Licardi

Elissa Hae-Kyung Lee

Steven Earl Bauer

Christopher Rawlins

Methods for repairing barrier coatings involving providing a component having a barrier coating including at least one damaged portion, removing the damaged portion of the barrier coating leaving a void, applying a replacement tape cast barrier coating to the void of the component, and sintering the component having the replacement tape cast barrier coating layer.

Methods for repairing barrier coatings

An article comprising a turbine component other than an airfoil having a metal substrate and a ceramic corrosion resistant coating overlaying the metal substrate. This coating has a thickness up to about one micrometer and consists of a ceramic composition that comprises a ceramic metal oxide selected from the group consisting of zirconia, hafnia and mixtures thereof. This coating can be formed by alternative methods to have different microstructures, including a dense matrix or a strain-tolerant columnar grain structure.

Turbine component other than airfoil having ceramic corrosion resistant coating and methods for making same

A process capable of depositing a diffusion coating of uniform thickness on localized surface regions of a component. The process makes use of an adhesive mixture containing a binding agent that is consumed as part of the deposition process so as not to negatively affect the quality and uniformity of the resulting coating. The process entails mixing a particulate donor material containing a coating element, a dissolved activator, and a particulate filler to form an adhesive mixture having a formable, malleable consistency. The adhesive mixture is applied to a surface of the component, and the component is heated to a temperature sufficient to vaporize and react the activator with the coating element of the donor material, thereby forming a reactive vapor of the coating element. The reactive vapor reacts at the surface of the component to form a diffusion coating containing the coating element.

Diffusion coating process

A process for forming diffusion aluminide coatings on an uncoated surface of a substrate, without interdiffusing a sufficient amount of aluminum into a coating layer to adversely affect the coating growth potential and mechanical properties of said coating layer. A metal substrate is provided comprising an external surface and an internal passage therein defined by an internal surface, at least a portion of the external surface of the substrate being coated with a coating layer selected from the group consisting of &#x3b2;-NiAl-base, MCrAlX, a line-of-sight diffusion aluminide, a non-line-of-sight diffusion aluminide, a pack diffusion aluminide, and a slurry diffusion aluminide on said substrate. The metal substrate is subjected to an aluminum vapor phase deposition process.

Method of selective region vapor phase aluminizing

A beta-phase nickel aluminide (NiAl) overlay coating () and method for modifying the grain structure of the coating () to improve its oxidation resistance. The coating () is deposited by a method that produces a grain structure characterized by grain boundaries () exposed at the outer coating surface (). The grain boundaries () may also contain precipitates () as a result of the alloyed chemistry of the coating (). During or after deposition, the overlay coating () is caused to form new grain boundaries () that, though open to the outer surface () of the coating (), are free of precipitates or contain fewer precipitates () than the as-deposited grain boundaries (). New grain boundaries () are preferably produced by causing the overlay coating () to recrystallize during coating deposition or after deposition as a result of a surface treatment followed by heat treatment.

Beta-phase nickel aluminide overlay coatings and process therefor

An article having an internal passage therein and an internal article surface is coated by providing a coating slurry that is a mixture of a deposition source including a source of aluminum, a halide activator, and a flowable carrier comprising a flowable compound selected from the group consisting of a flowable organic compound and a flowable inorganic compound. There is no oxide dispersant in the coating slurry. The coating slurry is introduced into the internal passage and dried to remove at least a portion of the carrier therefrom and leave a dried coating material. The article surface in gaseous communication with the dried coating material is heated to form an aluminum-containing coating bonded to the article surface. Any residual dried coating material is removed by blowing compressed air through the internal passage.

Method for coating an internal surface of an article with an aluminum-containing coating

A method for applying an aluminide coating on a gas turbine engine blade having an external surface and an internal cooling cavity having an internal surface that is connected to the external surface by cooling holes. The method is conducted in a vapor coating container having a hollow interior coating chamber, and includes the steps of loading the coating chamber with the blade to be coated; providing an aluminide coating gas in the loaded coating chamber; maintaining the loaded coating chamber comprising the aluminide coating gas at a specified temperature and time to deposit an aluminide coating on the external surface of the blade; and then flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified gas flow rate and time to move the aluminide coating gas through the cooling holes and internal cooling cavity and deposit an aluminide coating on the internal surface of the blade.

Aluminide coating of gas turbine engine blade

An article and TBC coating system thereon that in combination exhibit significantly improved spallation resistance. The article comprises a substrate formed of a metal alloy containing ruthenium and one or more refractory elements (e.g., tantalum, tungsten, molybdenum, rhenium, hafnium, etc.). The substrate is protected by a coating system comprising an aluminum-containing bond coat on the surface of the substrate and a ceramic coating bonded to the substrate by the bond coat. The bond coat, preferably an aluminide, is deposited so as to be substantially free of ruthenium, though ruthenium is present in the bond coat as a result of diffusion from the substrate into the bond coat.

Ni-base superalloy having a thermal barrier coating system

A method for applying an aluminide coating on a gas turbine engine blade having an external surface and an internal cooling cavity having an internal surface that is connected to the external surface by cooling holes. The method is conducted in a vapor coating container having a hollow interior coating chamber, and includes the steps of loading the coating chamber with the blade to be coated; providing an aluminide coating gas in the loaded coating chamber; flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified gas flow rate and time to move the aluminide coating gas through the cooling holes and internal cooling cavity and deposit an aluminide coating on the internal surface of the blade; and then flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified higher temperature and time to deposit an aluminide coating on the external surface of the blade.

Method for aluminide coating of gas turbine engine blade

A coating system for an article comprising a substrate formed of a metal alloy that is prone to the formation of a deleterious secondary reaction zone (SRZ) as a result of containing more than three weight percent rhenium and at least one additional refractory metal. The coating system comprises an aluminum-containing overlay coating and a diffusion barrier coating between the overlay coating and the substrate. The diffusion barrier coating consists of, in atomic percent, about 20% to about 90% ruthenium, about 2% to about 60% chromium, optionally up to about 50% aluminum, optionally up to about 20% of a platinum-group metal, and the balance at least one of nickel, cobalt, and iron and incidental impurities. The diffusion barrier coating sufficiently inhibits diffusion of aluminum from the overlay coating into the substrate, such that the substrate remains essentially free of SRZ.

Ni-Base superalloy having a coating system containing a diffusion barrier layer

A beta-phase NiAl overlay coating containing a dispersion of ceramic particles and a process for depositing the overlay coating. If the coating is used to adhere a thermal barrier coating (TBC), the TBC exhibits improved spallation resistance as a result of the dispersion of ceramic particles having a dispersion-strengthening effect on the overlay coating. The overlay coating contains at least one reactive element and is deposited so that the some of the reactive element deposits as the ceramic particles dispersed in the overlay coating.

Nickel aluminide coating and coating systems formed therewith

A protective overlay coating for articles used in hostile thermal environments, and particularly for use as a bond coat for a thermal barrier coating deposited on the coating. The coating is predominantly beta-phase NiAl into which a platinum-group metal is incorporated, yielding a coating system capable of exhibiting improved spallation resistance as compared to prior bond coat materials containing platinum, must notably the platinum aluminide diffusion coatings. A preferred composition for the beta-phase NiAl overlay coating further contains chromium and zirconium or hafnium.

A method for coating an article includes preparing a coating precursor paint including aluminum-containing pigment particles, a temporary organic binder comprising an acrylic, and a solvent for the temporary organic binder. The coating precursor paint is applied to a surface of the article and thereafter heated to a temperature of from about 1200&deg; F. to about 2100&deg; F. in a non-oxidizing environment.

Article protected by a diffusion aluminide coating applied by painting techniques

A predominantly beta-phase NiAl overlay coating for use as an environmental coating or a TBC bond coat for articles used in hostile thermal environments, such as components of a gas turbine engine. The coating contains up to about 4 atomic percent hafnium, such as in excess of 1.0 atomic percent hafnium. The coating may also contain about 2 to about 15 atomic percent chromium.

A gas turbine airfoil has an external surface and an internal passage therethrough. The internal passage is selectively coated by providing a source of a flowable precursor coating material in contact with the internal passage of the airfoil, and providing a coating prevention structure overlying at least a portion of the external surface. The flowable precursor coating material is flowed from the source of the flowable precursor coating material and through the internal passage of the airfoil. The coating prevention structure prevents contact of the flowable precursor coating material with the external surface of the airfoil.

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Blue Ash, OH, United States of America

Jeffrey Allan Pfaendtner