Honeywell International Inc.

Alliedsignal Inc.

Reza Oboodi

James Piascik

Bahram Jadidian

Eric Passman

Terence Whalen

Bjoern Schenk

Donald Martin Olson

Robert Franconi

Harry Lester Kington

Richard Bryce Fox

Martin Carlin Baker

Jimmy Wiggins

Paul Chipko

Leroy Allen Fizer

Jacob Harding

Lee Poandl

Gene Holden

Gary J Seminara

Natalie Kruk

Devlin M Gualtieri

Danial Lewis Kosht

Joseph M Walling

Daniel C Blazej

Richard Bye

Ronald J Louis

Michael C Janosik

Bjoem Schenk

James Plascik

Ionic liquid bath plating methods for depositing aluminum-containing layers utilizing shaped consumable aluminum anodes are provided, as are turbomachine components having three dimensionally-tailored, aluminum-containing coatings produced from such aluminum-containing layers. In one embodiment, the ionic liquid bath plating method includes the step or process of obtaining a consumable aluminum anode including a workpiece-facing anode surface substantially conforming with the geometry of the non-planar workpiece surface. The workpiece-facing anode surface and the non-planar workpiece surface are positioned in an adjacent, non-contacting relationship, while the workpiece and the consumable aluminum anode are submerged in an ionic liquid aluminum plating bath. An electrical potential is then applied across the consumable aluminum anode and the workpiece to deposit an aluminum-containing layer onto the non-planar workpiece surface. In certain implementations, additional steps are then performed to convert or incorporate the aluminum-containing layer into a high temperature aluminum-containing coating, such as an aluminide coating.

Methods and articles relating to ionic liquid bath plating of aluminum-containing layers utilizing shaped consumable aluminum anodes

A method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate to form an article is provided. The method includes the steps of etching the surface of the ceramic substrate to texture the surface, disposing an environmental barrier coating on the etched surface of the ceramic substrate. The environmental barrier coating includes a rare earth silicate, and pressure sintering the environmental barrier coating on the etched surface of the ceramic substrate in an inert or nitrogen atmosphere such that at least a portion of the environmental barrier coating is disposed in the texture of the surface of the ceramic substrate thereby forming the article.

Method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate

Methods for fabricating protective coating systems for gas turbine engine applications are provided. An exemplary method of applying a protective coating to a substrate includes the steps of providing a substrate formed of a ceramic matrix composite material, forming a first coating layer directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and forming a second coating layer directly on to the first coating layer and comprising a thermal barrier material. The method optionally includes forming a third coating layer partially directly on to the second coating layer and partially within at least some of the plurality of pores of the second coating layer.

Methods for fabricating protective coating systems for gas turbine engine applications

A protective coating system includes a substrate that has an exterior surface exhibiting a degree of valley/hill surface irregularity including a plurality of hills and a plurality of valleys and a first coating layer formed directly on to the exterior surface of the substrate and that conforms to the exterior surface of the substrate such that the first coating layer has a non-uniform coating thickness over the substrate. The protective coating system further includes a second coating layer formed directly on to the exterior surface of the first coating layer. The second coating layer includes a plurality of pores within the second coating layer. Still further, the protective coating system includes a third coating layer formed within at least some of the plurality of pores within the second coating layer.

Protective coating systems for gas turbine engine applications

A method for forming a protective coating on a surface of a ceramic substrate includes combining a rare-earth oxide, alumina, and silica to form a powder, etching the surface of the ceramic substrate, applying the powder on the etched surface in an amount of from about 0.001 to about 0.1 g/cmto reduce capture of bubbles from off-gassing of the ceramic substrate, heating the powder for a time of from about 5 to about 60 minutes to a temperature at or above the melting point such that the powder melts and forms a molten coating on the surface that has a minimized number of bubbles, and cooling the molten coating to ambient temperature to form the protective coating disposed on and in direct contact with the surface of the ceramic substrate such that the protective coating has a thickness of less than about 1 mil.

Method of forming a protective coating on a surface of a ceramic substrate

Methods for forming sintered-bonded high temperature coatings over ceramic turbomachine components are provided, as are ceramic turbomachine components having such high temperature coatings formed thereover. In one embodiment, the method includes the step or process of removing a surface oxide layer from the ceramic component body of a turbomachine component to expose a treated surface of the ceramic component body. A first layer of coating precursor material, which has a solids content composed predominately of at least one rare earth silicate by weight percentage, is applied to the treated surface. The first layer of the coating precursor material is then heat treated to sinter the solids content and form a first sintered coating layer bonded to the treated surface. The steps of applying and sintering the coating precursor may be repeated, as desired, to build a sintered coating body to a desired thickness over the ceramic component body.

Sintered-bonded high temperature coatings for ceramic turbomachine components

A method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate to form an article includes the steps of etching the surface of the ceramic substrate to texture the surface, disposing an environmental barrier coating on the etched surface of the ceramic substrate wherein the environmental barrier coating includes a rare earth silicate, and pressure sintering the environmental barrier coating on the etched surface of the ceramic substrate in an inert or nitrogen atmosphere at a pressure of greater than atmospheric pressure such that at least a portion of the environmental barrier coating is disposed in the texture of the surface of the ceramic substrate thereby forming the article.

Embodiments of laminated stator cores suitable for usage in high temperature applications are provided, as are embodiments of methods for manufacturing high temperature laminated stator core. In one embodiment, the method includes obtaining a plurality of coated laminates each comprising a laminate over which a coating precursor layer is formed. The coating precursor layer contain inorganic dielectric particles having a softening point. The plurality of coated laminates are arranged in a laminate stack, which is then fired at temperatures equal to or greater than the softening point of the inorganic dielectric particles. During firing, a compressive force is applied to the laminate stack sufficient to consolidate the inorganic dielectric particles into a plurality of coherent interlaminate dielectric layers electrically insulating and bonding together the plurality of coated laminates as the high temperature laminated stator core.

High temperature laminated stator cores and methods for the manufacture thereof

Protective coating systems for gas turbine engine applications and methods for fabricating such protective coating systems are provided. An exemplary protective coating system includes a substrate formed of a ceramic matrix composite material, a first coating layer formed directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and a second coating layer formed directly on to the first coating layer and comprising a thermal barrier material. The exemplary protective coating optionally includes a third coating layer partially formed directly on to the second coating layer and partially formed within at least some of the plurality of pores of the second coating layer.

Protective coating systems for gas turbine engine applications and methods for fabricating the same

Methods for manufacturing high temperature laminated stator cores

Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the high temperature electromagnetic coil assembly includes a coiled anodized aluminum wire and an electrically-insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded. The electrically-insulative, high thermal expansion ceramic body has a coefficient of thermal expansion greater than 10 parts per million per degree Celsius and less than the coefficient of thermal expansion of the coiled anodized aluminum wire.

High temperature electromagnetic coil assemblies

Components, turbochargers, and methods of forming components are provided. In an embodiment, by way of example only, a method of forming a component is provided. The method includes applying a plurality of coated particles to a substrate, wherein each coated particle comprises a solid film lubricant particle and a layer surrounding an entire surface of the solid film lubricant particle, each solid film lubricant particle comprises at least one compound, and the layer comprises a coating material having a greater resistance to oxidation than the compound when subjected to a predetermined processing temperature and heating the substrate to the predetermined processing temperature to form a portion of a coating over the substrate.

Components, turbochargers, and methods of forming the components

Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the method includes the steps of applying a high thermal expansion ceramic coating over an anodized aluminum wire, coiling the coated anodized aluminum wire around a support structure, and curing the high thermal expansion ceramic coating after coiling to produce an electrically insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded.

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Morris Plains, NJ, United States of America

Reza Oboodi