General Electric Company

Joseph David Rigney

Ramgopal Darolia

Jeffrey Allan Pfaendtner

Michael James Weimer

Irene T Spitsberg

William Scott Walston

David John Wortman

Jeffrey Allen Conner

Richard John Grylls

Ching-Pang Lee

Bangalore Aswatha Nagaraj

Nripendra Nath Das

Gillion Herman Marijnissen

Eric Richard Irma Carolus Vergeldt

Annejan Bernard Kloosterman

Bernard Patrick Bewlay

James Anthony Ruud

Pazhayannur Ramanathan Subramanian

Reed Roeder Corderman

Richard DiDomizio

Voramon Supatarawanich Dheeradhada

Melvin Robert Jackson

Yuk-Chiu Lau

Roger Dale Wustman

Joshua L Miller

Warren Davis Grossklaus, Jr

Robert Edward Schafrik

Brett Allen Rohrer Boutwell

Theodore Robert Grossman

Antonio Frank Maricocchi

Richard Arthur Nardi, Jr

Matthew David Saylor

John Lewis Lackman

Jon Conrad Schaeffer

Robert William Bruce

Dong-Sil Park

Brian Thomas Hazel

Michael Francis Xavier Gigliotti

Peter Joel Meschter

Gary Eugene Wheat

Mark Lloyd Miller

David Vincent Rigney

John Douglas Evans, Sr

Terri Kay Brown

Brent Ross Tholke

Mary Heppenstall-Butler

Janet Elizabeth Gaewsky

Karl S Fessenden

Thomas Joseph Cartier

Michael Francis Butler

Deborah Anne Schorr

William Evan McCormack

Elissa H Lee

Elissa Hae-Kyung Lee

David R Clarke

Jeff Pfaendtner

Ted Grossman

Eric Richad Irma Carolus Vergeldt

Christopher Rawlins

Karl Stephen Fessenden

A coating and process for depositing the coating on a substrate. The coating is a nickel aluminide overlay coating of predominantly the beta (NiAl) and gamma-prime (NiAl) intermetallic phases, and is suitable for use as an environmental coating and as a bond coat for a thermal barrier coating (TBC). The coating can be formed by depositing nickel and aluminum in appropriate amounts to yield the desired beta+gamma prime phase content. Alternatively, nickel and aluminum can be deposited so that the aluminum content of the coating exceeds the appropriate amount to yield the desired beta+gamma prime phase content, after which the coating is heat treated to diffuse the excess aluminum from the coating into the substrate to yield the desired beta+gamma prime phase content.

Coating systems containing beta phase and gamma-prime phase nickel aluminide

Coatings suitable for use as protective oxide-forming coatings on Nb-based substrates exposed to high temperatures and oxidative environments. The coatings contain chromium and/or molybdenum, preferably contains silicon, and optionally contains niobium, titanium, hafnium, iron, rhenium, tantalum, and/or tungsten, which in combination form multiple intermetallic phases, which in combination form one or more intermetallic phases that promote the formation of a slow-growing oxide scale. Depending on the particular coating composition, the intermetallic phases may be: a silicon-modified CrNb Laves phase and optionally a chromium solid solution phase, a CrNbSi intermetallic phase, and/or an MSi intermetallic phase where M is niobium, titanium, and/or chromium; or MSi, MSiand/or MSiwhere M is molybdenum, niobium, titanium, chromium, hafnium, iron, rhenium, tantalum, and/or tungsten.

Oxide-forming protective coatings for niobium-based materials

Nb&#x2014;Si based alloy articles comprising a Nb&#x2014;Si based alloy upon which is disposed an environmentally-resistant coating are described. They include a coating comprising at least one phase selected from the group consisting of M(Al,Si), M(Al,Si), and MSiAl, wherein M is one or more of Nb, Ti, Hf, Cr. Such coating can improve the environmental (e.g., in oxidation-promoting environments) resistance of a Nb&#x2014;Si based alloy and alloy articles. Methods for preparing these articles are described as well.

Nb-Si based alloys having an Al-containing coating, articles, and processes

A coating suitable for use as protective oxide-forming coatings on Nb-based substrates, and particularly monolithic niobium-based alloys, exposed to high temperatures and oxidative environments. The coating contains aluminum, may further contain silicon, and optionally contains niobium, titanium, hafnium, and/or chromium, which in combination form one or more intermetallic phases that promote the formation of a slow-growing oxide scale. The intermetallic phases may be M(Al,Si), M(Al,Si), and/or MSiAlwhere M is niobium, titanium, hafnium, and/or chromium.

According to an embodiment of the invention, a repaired component is disclosed. The repaired component comprises an engine run component having a base metal substrate, a portion of the base metal substrate between about 1-3 mils in thickness and an overlying bond coat having been removed to create a remaining base metal substrate of reduced thickness. The repaired component further comprises a lower growth environmental bond coating comprising an alloy having an aluminum content of about 10-60 atomic percent applied to the remaining base metal substrate so that upon subsequent repair of the component, less than about 1-3 mils in thickness of the remaining base metal substrate is removed because of less environmental coating growth into the substrate than the prior bond coat. Advantageously, the repaired component has extended component life and increased repairability.

Method for repairing components using environmental bond coatings and resultant repaired components

A coating and coating process for incorporating surface features on an air-cooled substrate surface of a component for the purpose of promoting heat transfer from the component. The coating process generally comprises depositing a first metallic coating material on the surface of the component using a first set of coating conditions to form a first environmental coating layer, and then depositing a second metallic coating material using a second set of coating conditions that differ from the first set, such that an outer environmental coating layer is formed having raised surface features that cause the surface of the outer environmental coating layer to be rougher than the surface of the first environmental coating layer.

Coating and coating process incorporating raised surface features for an air-cooled surface

Thermal barrier coating (TBC) and a method of depositing a TBC having a modulated columnar microstructure that exhibits increased impact resistance. The TBC is deposited to have a columnar microstructure in which columns extend from a substrate surface. The columns having inner regions contacting the surface, outer regions near an outermost surface of the TBC, and interior regions therebetween. The inner regions of the columns are substantially normal to the substrate surface and at least one of the interior and outer regions of the columns are nonaligned with its respective inner regions, so that the columns of the columnar microstructure are continuous but modulated between the inner and outer regions to reduce tensile stresses within the columns resulting from particle impact.

Thermal barrier coating with modulated grain structure and method therefor

An overlay coating for articles used in hostile thermal environments. The coating has a predominantly gamma prime-phase nickel aluminide (NiAl) composition suitable for use as an environmental coating and as a bond coat for a thermal barrier coating. The coating has a composition of, by weight, at least 6% to about 15% aluminum, about 2% to about 5% chromium, optionally one or more reactive elements in individual or combined amounts of up to 4%, optionally up to 2% silicon, optionally up to 60% of at least one platinum group metal, and the balance essentially nickel. A thermal-insulating ceramic layer may be deposited on the coating.

Coating systems containing gamma-prime nickel aluminide coating

A process for forming a beta-phase nickel aluminide (NiAl) overlay coating that is suitable for use as a bond coat for a thermal barrier coating (TBC). The overlay coating is deposited by a method that produces a generally columnar grain structure in which grains extend through the coating such that at least some grain boundaries are open at the coating surface. The coating is then peened with a particulate media, followed by heating the overlay coating to a temperature sufficient to cause the overlay coating to recrystallize and form new grain boundaries that are not open to the outer surface of the coating and significantly less susceptible to accelerated oxidation than the original grain boundaries. The particulate media is formed of a composition containing nickel and aluminum, such that an oxide scale that forms on the surface of the coating after the peening operation is substantially free of deleterious oxide compounds, notably iron-containing spinels.

Process for a beta-phase nickel aluminide overlay coating

A strengthened bond coat for improving the adherence of a thermal barrier coating to an underlying metal substrate to resist spallation without degrading oxidation resistance of the bond coat. The bond coat comprises a bond coating material selected from the group consisting of overlay alloy coating materials, aluminide diffusion coating materials and combinations thereof. Particles comprising a substantially insoluble bond coat strengthening compound and having a relatively fine particle size of about 2 microns or less are dispersed within at least the upper portion of the bond coat in an amount sufficient to impart strengthening to the bond coat, and thus limit ratcheting or rumpling thereof.

Strengthened bond coats for thermal barrier coatings

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

According to an embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, and improve upon the prior bond coat is disclosed. The method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the base metal substrate removed. The portion of the base metal substrate removed has a thickness, &#x394;t. The method also comprises applying a &#x3b2; phase NiAl overlay coating to the substrate, and determining the difference in thickness, &#x394;x, between the &#x3b2; phase NiAl overlay coating and the previously removed bond coat. The method further comprises reapplying the top ceramic thermal barrier coating to a nominal thickness of t+&#x394;t&#x2212;&#x394;x, wherein &#x394;t compensates for the portion of removed base metal substrate. Advantageously, the coated airfoil contour dimensions of the high pressure turbine blade are restored to about the coated dimensions preceding the engine run.

Method for repairing coated components using NiAl bond coats

According to an embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, is disclosed. The method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the base metal substrate removed. The portion of the base metal substrate removed has a thickness, &#x394;t. The method also comprises reapplying the diffusion bond coat to the substrate, wherein the bond coat is reapplied to a thickness, which is about the same as applied prior to the engine operation; and reapplying the top ceramic thermal barrier coating to a nominal thickness of t+&#x394;t, wherein &#x394;t compensates for the portion of removed base metal substrate. Advantageously, the coated airfoil contour dimensions of the high pressure turbine blade are restored to about the coated dimensions preceding the engine run.

Method for repairing coated components

Growing community of inventors

Milford, OH, United States of America

Joseph David Rigney