General Electric Company

Marcus P Borom

Wayne Charles Hasz

Curtis Alan Johnson

Lawrence E Szala

Dennis Michael Gray

Milivoj Konstantin Brun

Steven A Miller

Yuk-Chiu Lau

Paul Steven Svec

Frederic Joseph Klug

David Paul Mourer

Warren Arthur Nelson

Ronald H Arendt

Irvin C Huseby

Venkat Subramaniam Venkataramani

Minyoung Lee

Surinder Singh Pabla

James Anthony Brewer

Wayne D Pasco

Anthony Mark Thompson

John Schultz

Timothy Francis Bethel

Charles D Greskovich

Raj N Singh

William B Hillig

William A Morrison

Leonard V Interrante

James Edward Viggiani

Casimir W Krystyniak

Pritam L Ahuja

John Zanneti

A method for applying at least one bond coating on a surface of a metal-based substrate is described. A foil of the bond coating material is first attached to the substrate surface and then fused thereto, e.g., by brazing. The foil is often initially prepared by thermally spraying the bond coating material onto a removable support sheet, and then detaching the support sheet. Optionally, the foil may also include a thermal barrier coating applied over the bond coating. The substrate can be a turbine engine component.

Method of applying a bond coating and a thermal barrier coating on a metal substrate, and related articles

A method for applying a wear coating on a surface of a substrate is described. A foil of the wear coating is first attached to the substrate surface, and then fused to the surface, e.g., by brazing. The wear coating may be formed from a carbide-type material. The substrate is very often a superalloy material, e.g., a component of a turbine engine. A method for repairing a worn or damaged wear coating applied over a substrate is also described, along with related articles of manufacture.

Method of providing wear-resistant coatings, and related articles

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

An article having a spallation resistant TBC comprises a metal substrate, such as a high temperature superalloy, and a TBC, such as a coating of yttria stabilized zirconia. The TBC comprises a plurality of plasma-sprayed layers. The TBC has a coherent, continuous columnar grain microstructure, wherein at least one layer has a plurality of continuous columnar grains which have been extended by directional solidification into an adjacent layer.

Thermal barrier coatings having an improved columnar microstructure

An article is described, which includes a metal-based substrate, such as a superalloy; a dense, primary bond layer; and a spongy secondary bond layer. A thermal barrier coating is applied over the secondary bond layer. The spongy layer has a microstructure which includes an open network of interconnected pores. A process is also described. It includes the step of applying a spongy, metallic bond layer over the substrate, followed by the application of a thermal barrier coating. A dense, primary bond layer may optionally be applied before the application of the spongy layer.

Protective coatings for metal-based substrates, and related processes

A composite that protects thermal barrier coatings from the deleterious effects of environmental contaminants at operational temperatures is discovered. The thermal barrier coated parts have least two outer protective coatings that decrease infiltration of molten contaminant eutectic mixtures into openings in the thermal barrier coating.

Protected thermal barrier coating composite with multiple coatings

Method for modifying the surface of a thermal barrier coating, and related articles

An article having a spallation resistant TBC comprises a metal substrate, such as a high temperature superalloy, and a TBC, such as a coating of yttria stabilized zirconia. The TBC comprises a plurality of plasma-sprayed layers. The TBC has a coherent, continuous columnar grain microstructure, wherein at least one layer has a plurality of continuous columnar grains which have been extended by directional solidification into an adjacent layer. In a preferred embodiment, the coherent, continuous columnar microstructure comprises substantially all of the volume of TBC. A coherent, continuous columnar grain microstructure is also taught wherein at least some of the plurality of coherent, continuous columnar grains which comprise a TBC extend through essentially the entire thickness of the coating. A columnar crack pattern of cracks extending generally normal to the surface of the metal substrate is also developed within TBCs of the present invention in conjunction with the coherent, continuous columnar grain microstructures described.

Protective coatings for metal-based substrates and related processes

A method for providing a substantially-smooth protective coating on a metal-based substrate is disclosed. A thermal barrier coating is first applied over the substrate by plasma-spraying. The coating is then plasma-heated according to a time- and temperature schedule sufficient to re-melt its surface region, allowing the coating material to flow and smoothen. The surface region is then allowed to cool to a temperature below its melting point. After being cooled, the surface is much smoother than when originally applied, which allows the coating to be used in a higher-temperature environment. The coating is often zirconia-based, e.g., yttria-stabilized zirconia.

Method for modifying the surface of a thermal barrier coating by

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

A method and apparatus form a thermal barrier coating on a metal component. A molten thermal barrier coating powder is sprayed on the component in sweeping strokes. A plurality of overlapping solidified coating ribbons are deposited on the component and include a sequentially deposited surface ribbon forming sublayer ribbons therebelow. The surface ribbon is preheated at a spray site so that the sprayed molten powder remelts the surface ribbon at the spray site for sequentially welding the sequentially deposited surface ribbons to the sublayer ribbons.

Directionally solidified thermal barrier coating

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Schenectady, NY, United States of America

Marcus P Borom