Honeywell International Inc.

Murali N Madhava

Derek Raybould

Yiping Hu

Federico Renteria

George Reimer

Timothy R Duffy

Margaret M Floyd

William F Hehmann

Vincent Chung

Amol R Gholkar

Huu-Duc Trinh-Le

There is provided a method for applying an improved chromium diffusion coating on an industrial item such as a turbine blade of a gas turbine engine. Chromium and other active metals are combined to form an alloy coating. Active elements include silicon, hafnium, zirconium, yttrium, tantalum, and rhenium. For producing the modified coatings through pack cementation chromium and a master alloy are mixed into a packing along with inert material and a halide activator. The packing surrounds a target in a diffusion box. The metals are then deposited by diffusion onto a target surface by pack cementation methods. The diffusion of the desired metals takes place during a coating thermal cycle. Alternatively, the diffusion can take place using an out-of-pack arrangement. Such modified coatings are utilized as improved performance coatings for environmental resistance applications over the current chromium diffusion coatings.

Chromiumm diffusion coatings

A quasi-single phase or single phase thick platinum nickel aluminide coating and methods for forming the coating over a nickel-based superalloy substrate are provided. The method includes the steps of forming a metal layer over a surface of the nickel-based superalloy substrate, the metal layer comprising platinum, growing a diffusion zone comprising a platinum nickel alloy layer from the metal layer and the nickel-based superalloy substrate, and subjecting the platinum nickel alloy to one or more aluminization cycles to transform the platinum nickel alloy into a platinum nickel aluminide coating having a platinum aluminide phase formed therein.

Method for forming thick quasi-single phase and single phase platinum nickel aluminide coatings

The present invention thus provides an improved method for coating turbine engine components. The method utilizes a cold high velocity gas spray technique to coat turbine blades, compressor blades, impellers, blisks, and other turbine engine components. These methods can be used to coat a variety of surfaces thereon, thus improving the overall durability, reliability and performance of the turbine engine itself. The method includes the deposition of powders of alloys of nickel and aluminum wherein the powders are formed so as to have an amorphous microstructure. Layers of the alloys may be deposited and built up by cold high velocity gas spraying. The coated items displayed improved characteristics such as hardness, strength, and corrosion resistance.

Methods of forming high strength coatings

The present invention provides methods and materials for use in applying a coating on a surface of a magnesium component. The method includes the steps of: accelerating a coating powder to a velocity of between about 500 to about 1200 meters/second, wherein the coating powder comprises a material selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, and composites; directing the coating powder through a convergent-divergent nozzle onto the surface of the magnesium component; and forming a coating on the surface of the magnesium component so as to substantially cover the surface of the magnesium component. The coating thickness may be between approximately 0.1 to approximately 1.0 mm.

Methods for coating a magnesium component

There is provided a method for depositing a modified MCrAlY coating on a surface of a gas turbine engine component. The method includes cold gas dynamic spraying techniques to provide a metallurgical bond between a substrate, such as a superalloy substrate, and the modified MCrAlY composition. The method further includes post deposition heat treatments including hot isostatic pressing. The modified MCrAlY composition includes one or more elements of Pt, Hf, Si, Zr, Ta, Re, Ru, Nb, B, and C, which improves the corrosion and environmental resistance of the coated component.

Method for applying environmental-resistant MCrAlY coatings on gas turbine components

Methods for repair of single crystal superalloys by laser welding and products thereof have been disclosed. The laser welding process may be hand held or automated. Laser types include: CO, Nd:YAG, diode and fiber lasers. Parameters for operating the laser process are disclosed. Filler materials, which may be either wire or powder superalloys are used to weld at least one portion of a single crystal superalloy substrate.

Methods for repair of single crystal superalloys by laser welding and products thereof

The present invention provides a chromium and active elements modified platinum aluminide coating that may be used on a surface of a gas turbine engine component such as a turbine blade. The coating may be used as a protective coating that impedes the progress of corrosion, oxidation, and sulfidation in superalloy materials that comprise the substrate of the turbine blade. Additionally, the coating may be used as a bond coat onto which a thermal barrier coating is deposited. The presence of active elements as well as chromium and platinum provides improved corrosion, oxidation, and sulfidation resistance. The coating is applied using an electron beam physical vapor deposition. The coating is applied alternatively using selected sequential diffusion processing steps involving chromium, platinum and aluminum.

Chromium and active elements modified platinum aluminide coatings

A new method for repairing turbine engine components is provided. The method utilizes a cold gas-dynamic spray technique to repair degradation on turbine blades, vanes and other components. In the cold gas-dynamic spray process particles at a temperature below their fusing temperature are accelerated and directed to a target surface on the turbine blade. When the particles strike the target surface, the kinetic energy of the particles is converted into plastic deformation of the particle, causing the particle to form a strong bond with the target surface. Post-spray processing is then performed to consolidate and homogenize the applied materials and restore integrity to the material properties in the repaired turbine component. Thus, the cold gas-dynamic spray process and post-spray processing can be employed to effectively repair degraded areas on gas turbine components.

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Chicago, IL, United States of America

Murali N Madhava