General Electric Company

Lawrence E Szala

Minyoung Lee

Marcus P Borom

Milivoj Konstantin Brun

Steven A Miller

Paul Steven Svec

Robert C DeVries

David Paul Mourer

Roy E Tuft

Robert C De Vries

Bangalore Aswatha Nagaraj

Venkat Subramaniam Venkataramani

Wayne Charles Hasz

James Anthony Brewer

D Sangeeta

David Winfield Woodruff

Clifford L Spiro

William R Reed, Jr

Louis E Hibbs, Jr

Daniel Scott McAtee

James Anthony Ruud

Curtis Alan Johnson

Yuk-Chiu Lau

Dennis Michael Gray

Hrishikesh Keshavan

Atanu Saha

Kevin Paul McEvoy

Susan Corah

Marcus Preston Boron

The present invention is directed to repair compositions for thermal barrier coatings and methods of use thereof. The repair compositions include a ceramic composition, a colloidal solution, an aqueous binder, an aqueous dispersant, and an aqueous ammonia solution. The ceramic composition includes a first population of yttria-stabilized zirconia particles having a mean diameter from about 250 nm to about 1000 nm, a second population of yttria-stabilized zirconia particles having a mean diameter from about 2 &#x3bc;m to about 10 &#x3bc;m, and a third population of yttria-stabilized zirconia particles having a mean diameter from about 20 &#x3bc;m to about 250 &#x3bc;m. One method includes depositing the repair layer onto the damaged region, the repair layer including the repair composition, and heat treating the repair layer.

Thermal barrier coating repair compositions and methods of use thereof

A curable masking material for protecting a passage hole in a metal-based substrate is formed of an extrudable resin composition. The resin composition is thermally stable at elevated temperatures, and does not serve as an adhesion site for any coatings which are applied over the masking material. In addition, the resin composition has non-Newtonian flow characteristics and is adapted to form a protrusion extending from the passage hole upon extrusion to fill the passage hole.

Curable masking material for protecting a passage hole in a substrate

A method for improving the quality of a zirconia-based coating deposited on a metal-based substrate is disclosed. The method comprises the step of plasma-spraying zirconia powder of substantially uniform particle size onto the substrate. The disclosure further relates to an improved powder source material for use in a plasma. The source material is zirconia powder having a uniform particle size, and optionally, a uniform particle density. The use of such a material results in improved thermal barrier coatings for various substrates, such as those found in a turbine engine.

Method to improve the service life of zirconia-based coatings applied by

An improved thermal barrier coating for metal substrates such as superalloys is disclosed. The coating is a slurry composition, comprising spheres of zirconia, at least some of which are hollow, contained within a porous oxide matrix, such as aluminosilicate. The slurry composition can be applied by slurry casting or similar techniques to the desired surface. Coating methods are also described. In general, they involve the application of successive layers of variations of the slurry composition, with various curing techniques used between layers and after the final coating is applied. Another embodiment of this invention embraces a composite coating, comprising (i) an oxide matrix phase; (ii) zirconia spheres embedded in the oxide matrix; and (iii) a porous phase.

Coating composition for metal-based substrates, and related processes

A method for temporarily protecting at least one passage hole in a metal-based substrate from being obstructed by at least one coating applied over the substrate is disclosed. The method includes the following steps:

Method for protecting passage holes in a metal-based substrate from

An improved thermal barrier coating for metal substrates such as superalloys is provided. The coating is a slurry composition, comprising spheres of zirconia, at least some of which are hollow, contained within a porous oxide matrix, such as aluminosilicate. The slurry composition can be applied by slurry casting or similar techniques to the desired surface. Coating methods involve the application of successive layers of variations of the slurry composition, with various curing techniques used between layers and after the final coating is applied. Another embodiment of this invention embraces a composite coating, comprising (i) an oxide matrix phase; (ii) zirconia spheres embedded in the oxide matrix; and (iii) a porous phase.

A transfer tube is produced comprised of a high density ceramic oxide tube having directly bonded to its outer surface wall a low density ceramic oxide shell.

Transfer tube

An integral transfer tube is produced comprised of a hollow high density ceramic oxide tube having its outer surface wall surrounded by a low density multilayered ceramic oxide shell, and having a heating element comprised of a heating wound portion and two end portions wherein the wound portion is intermediate the tube and the shell, and wherein at least a sufficient amount of the end portions are exposed for electrical attachment.

Method for producing heat transfer tube with insitu heater

Molten metal transfer tube

A transfer tube is produced comprised of a high density ceramic oxide tube having a low density multi-layered ceramic oxide shell directly bonded to its outer surface wall.

An integral transfer tube is produced comprised of a hollow high density ceramic oxide tube having its outer surface wall surrounded by a low density ceramic oxide shell, and having a heating element comprised of a heating wound portion and two end portions wherein the wound portion is intermediate the tube and the shell, and wherein at least a sufficient amount of the end portions are exposed for electrical attachment.

Transfer tube with in situ heater

Transfer tube with insitu heater

High-strength, fine-grain, multi-phase substantially crystalline sintered ceramic bodies are produced by a process comprising the steps of cold pressing, followed by sintering at a high temperature, of a mixture of different powdered ceramic materials containing non-inhibitory components and a source of inhibitory components that can chemically interact at elevated temperatures generate gases which hinder densification or form phases undesirable for sintering provided that there is also included in the mixture an amount of a source of a component co-reactive with the gases produced by the inhibitory components at elevated temperature to achieve efficient densification and retention of properties in the sintered body.

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Scotia, NY, United States of America

Lawrence E Szala