United Technologies Corporation

Hamilton Standard Controls, Inc.

Essex Group, Inc.

Norman S Bornstein

Michael A DeCrescente

John G Smeggil

Stephen Chin

David N Duhl

Donald R Parille

Dilip M Shah

Roscoe A Pike

Francis J Wallace

John P Wesson

John J Brennan

William Patrick Allen

Mohammad F Zaman

Clyde O Brown

Raymond A Zatorski

Dennis L Peppler

Marvin E Hartz

Hilton A Roth

Raymond F Zatorski

Michael A De Crescente

A compressor coating is described which can reduce corrosion in the turbine system of a gas turbine engine. The coating is essentially not wet by droplets or aerosols of sea water or other corrodants. The coating reduces the build up of salt deposits on compressor components and their subsequent passage into the turbine section, thereby preventing severe localized corrosion which would otherwise occur.

Method of reducing corrosion in gas turbine engines

An overcoat is applied over thermal barrier coatings such as YSZ or other columnar grain ceramic. The exposed surface of the TBC is prepared to ensure that it is clean and has a proper roughness. The surface is then heated and an overcoat material such as a solid solution of chromia and alumina is deposited on the exposed surface, for example by plasma spraying to form a continuous overcoat on the TBC. The overcoat is preferably corrosion and erosion resistant, and inhibits the migration of oxygen to the underlying TBC and alumina layer.

Method of applying an overcoat to a thermal barrier coating and coated

The present invention relates to a thermal barrier coated article with spallation and delamination inhibiting metallic bond coat. The metallic bond coat contains a reactive element oxide, preferably yttria, which reacts with sulfur, typically migrating from the substrate to the thermal barrier coating, to prevent the sulfur from inducing spallation of the oxide scale at the interface of the thermal barrier coating and the metallic bond coat. This metallic bond coat is preferably multi-layered having a reactive element oxide containing layer sandwiched between two reactive element oxide-free layers.

Spallation/delamination resistant thermal barrier coated article

Single crystal superalloy castings are described which have excellent oxidation resistance. The oxidation resistance is due to the presence of small but effective amounts of magnesium in the casting. Single crystal castings containing magnesium in the range of 5-200 parts per million, by weight, are described.

Method of making oxidation resistant single crystal superalloy castings

A corrosion inhibited fuel mixture includes a hydrocarbon fuel, at least one vanadium composition, and a yttrium composition. The concentration of the yttrium composition in the mixture provides at least a stoichiometric amount of yttrium for a substantially complete reaction between the yttrium and V.sub.2 O.sub.5 formed from the vanadium composition when the mixture is burned. The yttrium and V.sub.2 O.sub.5 react to form YVO.sub.4. One particular yttrium composition useful as a hydrocarbon fuel soluble, water stable vanadium corrosion inhibitor incorporates a yttrium ester having at least four carbon atoms and a hydrocarbon fuel soluble chelating agent that includes 2,4-pentanediene. The complex has a molar ratio of 2,4-pentanediene to yttrium of up to 5:1.

Vanadium corrosion inhibitor

Oxidation resistant single crystal superalloy castings

Molybdenum disilicide base materials and methods for producing them are described. Mixtures of MoSi.sub.2 powder and other powders including SiO.sub.2, Si.sub.3 N.sub.4, SiC and Mo.sub.5 Si.sub.3 are plasma sprayed. Another embodiment which involves oxidation of MoSi.sub.2 is also disclosed. The resistant materials have particular utility as coatings for Nb alloys.

Molybdenum disilicide based materials with reduced coefficients of

Superalloy articles are made more oxidation resistant by a process which includes heat treating the article in the presence of foreign chemical species, at a temperature at which the foreign chemical species reacts with and modifies any oxide film present on the article surface. The heat treatment is best carried out at a temperature above the gamma prime solvus temperature of the article and below the incipient melting temperature of the article. Alternatively, the heat treatment may be carried out within the range defined by the incipient melting temperature of the article and about 150.degree. C. below the incipient melting temperature of the article. At such temperatures the foreign chemical species reacts with and modifies the oxide film on the article surface. Sulfur is then able to diffuse through such modified film, and a more oxidation resistant component is produced.

Method for removing sulfur from superalloy articles to improve their

Thermomechanical fatigue failure in components in high performance gas turbine engines is diminished by providing the component with an overlay of a metallic coating and a strain isolating layer located between the surface of the component and the metallic coating overlay.

Thermal fatigue resistant coatings

According to this invention, the oxidation resistance of alumina scale forming nickel based superalloys is significantly improved by controlling the level of sulfur in the alloy composition. According to one preferred embodiment of the invention, the superalloys contain less than 5 parts per million, by weight, of sulfur. Most preferably, they contain less than 2 parts per million, by weight, of sulfur.

Oxidation resistant superalloys containing low sulfur levels

A silver base electrical contact material is described which contains a dispersion of particles consisting of cadmium oxide and nickel. The nickel particles are surrounded by a continuous adherent coating of nickel oxide which eliminates the detrimental reaction which would otherwise occur between nickel and cadmium oxide. The invention contact materials have improved lives and are fabricated by any one of several different powder metallurgy techniques.

Composite silver base electrical contact material

A high speed method of producing continuous length magnet wire coated with a high solids content polymer coating composition. Copper or copper alloy wire segments are joined by brazing utilizing a braze whose melting point is greater than 1000.degree. F. and less than 1600.degree. F. The thus formed joint has a tensile strength greater than 27,000 p.s.i., and is capable of being conformed to the circumference of the wire substrate without substantially altering the surface integrity of the wire. The continuous length magnet wire is preheated to an elevated temperature. The preheated wire is coated with a noncirculating polymer enamel composition having a high solids content and a high viscosity at high speed. The enamel coated wire is then cured.

Method for producing continuous length high solids enamel coated magnet

The high temperature properties of protective coatings, paricularly the oxidation resistance, is improved by the melting of a surface portion of the coating using a high intensity energy source. The surface melting refines and homogenizes the coating structure, thereby eliminating defects which would otherwise cause premature coating failure.

High temperature coatings by surface melting

An improved hot dip coating of the zinc aluminum type contains germanium (Ge). In Zn-10Al coatings the addition of 0.1-1.2 Ge weight percent increases the fluidity of the molten metal in the bath and thereby enables substantially thinner coatings having more refined phase structure. Silicon (Si) is found to exhibit an analogous effect, but it not as powerful as Ge. Improved coatings contain zinc, 7-17Al, and 0.1-3(Ge+Si), where Ge ranges from 0-1.2, all weight percent.

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West Hartford, CT, United States of America

Norman S Bornstein