General Electric Company

Other

Mark Daniel Gorman

Ramgopal Darolia

Irene T Spitsberg

Bangalore Aswatha Nagaraj

Brett Allen Rohrer Boutwell

Robert William Bruce

Brett Allen Boutwell

Curtis Alan Johnson

Brian Thomas Hazel

Yan Gao

Melvin Robert Jackson

Liang Jiang

Christine Govern

Venkat Subramanian Venkataramani

Venkat Subramaniam Venkataramani

Andrew Philip Woodfield

Michael Francis Xavier Gigliotti

Jerry Donald Schell

Ching-Pang Lee

Michael James Weimer

Ji-Cheng Zhao

David Edwin Budinger

Stephen Joseph Ferrigno

Michael F Gigliotti, Jr

Charles Gitahi Mukira

Anthony Mark Thompson

Warren Davis Grossklaus, Jr

Robert Edward Schafrik

Matthew J Stewart

Robert George Zimmerman, Jr

Shesh Krishna Srivatsa

Gary Edward Trewiler

Ming Fu

Philemon Kennard Wright, Iii

David John Dietz

Thomas F Berry

Barbara Ann Link

Romgopal Darolia

Jiang Liang

William Bizer

Antonio Mogro-Campera

Warren Davis Grossklaus

Ramgopal Dorolia

Jr Robert George Zimmerman

A coating process and system suitable for use on components subjected to high temperatures. The coating system includes an overlay coating of predominantly B2 phase rhodium aluminide (RhAl) intermetallic compound containing about 25 to about 90 atomic percent rhodium, about 10 to about 60 atomic percent aluminum, optionally up to a combined total of about 25 atomic percent of one or more platinum group metals chosen from the group consisting of platinum, palladium, ruthenium, and iridium, and up to about 20 atomic percent of the base metal and alloying constituents of the substrate. The RhAl intermetallic coating may serve as an environmental coating, a diffusion barrier layer for an overlying environmental coating, or both, with or without an outer ceramic coating.

Coating systems containing rhodium aluminide-based layers

A coating process for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating process forms a coating system that includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.

Process of applying a coating system

Thermal barrier coating systems for use with hot section components of a gas turbine engine include an inner layer overlying a bond coated substrate and a top layer overlying at least a portion of the inner layer. The inner layer includes a thermal barrier material such as yttria-stabilized zirconia. The top layer includes a rare earth aluminate. The thicknesses and microstructures of the layers may be varied depending on the type of component to be coated. Articles incorporating the thermal barrier coating system exhibit improved resistance to CMAS infiltration.

Thermal barrier coating systems including a rare earth aluminate layer for improved resistance to CMAS infiltration and coated articles

A gas turbine engine turbine blade comprising an airfoil section, a platform section, an under platform section, and a dovetail section, an exterior surface of the dovetail section comprising a shank exterior surface and a serrated exterior surface. The blade further comprises a silicon-modified diffusion aluminide layer a surface of a turbine blade section selected from the group consisting of an exterior surface of the under platform section, the exterior surface of the dovetail section, and combinations thereof, the silicon modified diffusion aluminide layer having a concentration of silicon at a surface of the silicon-modified diffusion aluminide layer in the range of about 1 weight percent to about 10 weight percent and a concentration of aluminum at the surface of the silicon modified diffusion aluminide layer in the range of about 5 weight percent to about 25 weight percent.

Corrosion coating for turbine blade environmental protection

A process for protecting a thermal barrier coating (TBC) on a component used in a high-temperature environment, such as the hot section of a gas turbine engine. The process applies a protective film on the surface of the TBC to resist infiltration of contaminants such as CMAS that can melt and infiltrate the TBC to cause spallation. The process generally entails applying to the TBC surface a metal composition containing at least one metal whose oxide resists infiltration of CMAS into the TBC. The metal composition is applied so as to form a metal film on the TBC surface and optionally to infiltrate porosity within the TBC beneath its surface. The metal composition is then converted to form an oxide film, with at least a portion of the oxide film forming a surface deposit on the TBC surface.

Process for forming thermal barrier coating resistant to infiltration

According to an embodiment of the invention, an article of manufacture for use in a gas turbine engine is disclosed. The article comprises a part having a surface covered with a ceramic thermal barrier coating. The thermal barrier coating has an outer surface covered with a sacrificial phosphate coating, wherein the sacrificial phosphate coating reacts with contaminant compositions to prevent contaminant infiltration into the thermal barrier coating.

Protection of thermal barrier coating by a sacrificial coating

A method for making a gas turbine engine turbine blade comprising an airfoil section a platform section, an under platform section, and a dovetail section, the exterior surface of the dovetail section comprising a shank exterior surface and a serrated exterior surface. The blade further includes a silicon-modified diffusion aluminide layer a surface of a turbine blade section selected from the group consisting of the exterior surface of the under platform section, the exterior surface of the dovetail section, and combinations thereof, the aluminide layer having a concentration of silicon at a surface of the aluminide layer in the range of about 1 weight percent to about 10 weight percent and a concentration of aluminum at the surface of the aluminide layer in the range of about 5 weight percent to about 25 weight percent.

A damaged gas turbine blade which has previously been in service, and which is made of a base metal, is furnished. Any damaged material is removed from the damaged blade tip. The damaged blade tip is weld repaired with a nickel-base superalloy that is more resistant to oxidation resistance than is the base metal in the operating environment of the tip-repaired gas turbine blade. The method does not include any step of coating a lateral surface of the repaired blade tip with a non-ceramic coating after the step of weld repairing.

Repair of gas turbine blade tip without recoating the repaired blade tip

A turbine airfoil having an improved impact and erosion resistance. The airfoil comprises: (a) a base segment having an impact resistant leading edge section proximate to the leading edge comprising a material having having a yield strength of least about 250 ksi and an elongation percentage of about 12% or less; and (b) an erosion resistant coating overlaying the base segment at least in the leading and trailing edge portions of the pressure side, the erosion resistant coating comprising at least one ceramic layer having at least one of the following properties: (1) an erosion value of at least about 200 g. of erodent to cause a thickness loss of about 15-20 microns; (2) an erosion volume loss value (V) of about 1.9 or less as defined by the equation V=H&#xd7;E&#xd7;Fwhere H is hardness, E is elastic modulus and F is fracture toughness; and (3) an F value of at least about 1.5 MPa*m. The erosion resistant coating can comprise alternating ceramic and metallic layers and is typically formed by a method involving the step of forming on the pressure side of the base segment of the airfoil in alternating fashion at least one ceramic layer and at least one metallic layer.

Airfoil having improved impact and erosion resistance and method for preparing same

In accordance with an embodiment of the invention, an article is provided. The article comprises a substrate comprised of silicon containing material, an environmental barrier coating (EBC) overlying the substrate and a thermal barrier coating (TBC) on the environmental barrier coating. The thermal barrier coating comprising a compound having a rhombohedral phase.

Method for producing a thermal barrier coating/environmental barrier coating system

A coating process and system for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating system includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.

Ni-base superalloy having a coating system containing a stabilizing layer

In accordance with an embodiment of the invention, a thermal barrier coating for inclusion in a thermal barrier coating system is provided. The thermal barrier coating comprises a compound having a rhombohedral phase. In accordance with another embodiment of the invention, a thermal barrier coating is provided that comprises a compound having the formula of: ABO, wherein A is at least one rare earth element; and B is selected from the group consisting of Zr, Hf and mixtures thereof.

Method for producing a thermal barrier coating on a substrate

A modified platinum group metal coating composition comprising a phase having a solid solution face-centered cubic (fcc) crystal structure, rich in platinum group materials. In order to be effective, the platinum group metal coating material was modified based on the chemical composition and chemical activity of the substrate material. The platinum group metal coating material was modified to include, in solid solution, elements of the superalloy substrate, specifically nickel (Ni) and cobalt (Co). Depending on the substrate material, the modified platinum group metal coating material may not even include Ni or Co, but may be modified to include amounts of different elements that are consistent with the chemical composition of the substrate. The modified platinum metal coating material also includes aluminum (Al). The composition may include small amounts of a second phase isolated within the fcc phase matrix.

Platinum group bond coat modified for diffusion control

Low thermal conductivity thermal barrier coating system and method therefor

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West Chester, OH, United States of America

Mark Daniel Gorman