Sulzer Metco (us) Inc.

Sulzer Metco Venture LLC

Sulzer Metco Ag

Oerlikon Metco Ag, Wohlen

Sulzer Metco Inc.

Oerlikon Metco Inc.

Richard Karl Schmid

Jacobus Cornelis Doesburg

Mitchell R Dorfman

Liangde Xie

Matthew Gold

David S Gollob

Thomas H Piquette

Jacobus C Doesburg

Omar Basil Al-Sabouni

James Derby

David Hawley

Gerard Barbezat

Malko Gindrat

Arno Refke

Luis F Correa

Christopher G Dambra

Komal Laul

Omar Sabouni

Alexander Barth

Dario Russo

Farshad Ghasripoor

Jacobus Comelius Doesburg

David Gollob

Jacobus Doesburg

Jacobus Cornelius Doesburg

Plasma nozzle includes a nozzle body arranged to engage with a thermal spray gun. The nozzle body includes an axial through bore having up-stream input orifice and a down-stream nozzle exit, at least one material injector positioned between the up-stream input orifice and the nozzle-exit, said at least one material injector being configured to introduce a feedstock material into a gas flow passing through the axial through bore and at least one gas injector configured to introduce a shroud gas flow into the axial through bore and being located at a position up-stream of said at least one material injector.

Plasma nozzle for a thermal spray gun and method of making and utilizing the same

A method for forming a ceramic containing composite structure is proposed comprising the steps of (a) feeding a ceramic component that sublimes and a metallic or semi-conductor material that does not sublime into a thermal spray apparatus, (b) spraying the ceramic component and the metallic or semi-conductor material onto a substrate, whereby the ceramic component and the metallic or semi-conductor material deposit on the surface of the substrate, and (c) keeping the metallic or semi-conductor material on the substrate surface plastic during spraying at least in the region where the metallic or semi-conductor material actually strikes the surface.

Method for forming ceramic containing composite structure

The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.

High purity ceramic abradable coatings

A solder composition for forming a solder joint. The composition includes a powder material including a solid metal matrix material and a filler material. The solid metal matrix material includes one or more of tin-silver-copper (Sn&#x2014;Ag&#x2014;Cu), tin-copper (Sn&#x2014;Cu), tin-copper-nickel (Sn&#x2014;Cu&#x2014;Ni), tin-silver (Sn&#x2014;Ag), tin-silver-bismuth (Sn&#x2014;Ag&#x2014;Bi), tin-bismuth-indium (Sn&#x2014;Bi&#x2014;In), tin-gold (Au&#x2014;Sn), tin-zinc (Sn&#x2014;Zn), tin-zinc-bismuth (Sn&#x2014;Zn&#x2014;Bi), tin-bismuth-silver (Sn&#x2014;Bi&#x2014;Ag), tin (Sn), tin-indium (Sn&#x2014;In), indium (In), indium-silver (In&#x2014;Ag), and tin-lead (Sn&#x2014;Pb). The filler material includes one or more of copper (Cu), gold (Au), nickel (Ni), nickel-gold (Ni&#x2014;Au), carbon, silver (Ag), aluminum (Al), molybdenum (Mo), nickel (Ni) or nickel-gold (Ni&#x2014;Au) coated carbon, the platinum group metals (PGM's), and their alloys.

Material and method of manufacturing of a solder joint with high thermal conductivity and high electrical conductivity

The invention is directed to high purity zirconia-based and/or hafnia-based materials and coatings for high temperature cycling applications. Thermal barrier coatings made from the invention high purity material was found to have significantly improved sintering resistance relative to coatings made from current materials of lower purity. The invention materials are high purity zirconia and/or hafnia partially or fully stabilized by one or any combinations of the following stabilizers: yttria, ytterbia, scandia, lanthanide oxide and actinide oxide. Limits for impurity oxide, oxides other than the intended ingredients, that lead to significantly improved sintering resistance were discovered. High purity coating structures suitable for high temperature cycling applications and for application onto a substrate were provided. In one structure, the coating comprises a ceramic matrix, porosity and micro cracks. In another structure, the coating comprises a ceramic matrix, porosity, macro cracks and micro cracks. In another structure, the coating comprises ceramic columns and gaps between the columns. In another structure, the coating comprises ceramic columns, gaps between the columns and nodules distributing randomly in the gaps and columns.

Optimized high temperature thermal barrier

A mechanical seal structure and a method for manufacture that employs at least one ceramic seal face prepared by a thermal spray process.

Mechanical seals and method of manufacture

The invention relates to a thermal spray feedstock composition that employs free flowing agglomerates formed from (a) a ceramic component that sublimes,(b) a metallic or semi-conductor material that does not sublime and (c) a binder. The invention also relates to a method for preparing the agglomerates and a method for preparing ceramic containing composite structures from the agglomerates.

Thermal spray feedstock composition

The present invention provides a powder blend or composite powder that is fed into a kinetic spray device, accelerated towards a substrate or part in order to form a composite solder with thermal and electrical properties better than existing solder. The other advantages of building a solder layer in this manner include a low oxide content to improve subsequent solderability, excellent control of the deposition thickness, excellent control of the deposition chemistry and lastly, high speed of manufacture.

Material and method of manufacture of a solder joint with high thermal conductivity and high electrical conductivity

A method of coating a substrate by thermal application of the coating materials using a plasma jet is disclosed. The properties of the plasma jet are determined by controllable process parameters. The coating material and a process gas mixture are injected into the plasma jet where the coating material is partly or completely evaporated depending on the controllable parameters. The phases of the coating material present in vapor and, optionally, condensed form are at least partly deposited on the substrate. A diagnostic measuring method determines the relative proportion of vapor and/or condensed phase for the coating material transported in the plasma jet. The controllable process parameters are set with respect to desired values using such measured data. Regulation of direct manufacture of the coating, particularly a multi-layer coating system, is carried out with respect to these desired values, which correspond to a predetermined vapor or condensed phase proportion.

Method of coating a substrate by a thermal application of the coating material

A pre-alloyed stabilized zirconia powder suitable for use in thermal barrier applications is formed by alloying zirconia with a stabilizer, such as yttria, and processing the alloyed stabilized zirconia to form a very fine powder. The raw powder is then spray-dried to produce an agglomerated powder having an average particle size suitable for use in spray coating applications. The resulting powder can be used in a thermal-spray application to produce a porous thermal barrier coating having a substantially decreased thermal conductivity when compared to conventional TB coatings, such those produced using plasma-densified powders.

Method of producing a pre-alloyed stabilized zirconia powder

A granular composition is applied to tips of rotor blades utilized in a gas turbine engine wherein the blade tips rub against an abradable ceramic layer. Individual grains each have a core of silicon carbide and a layer of aluminum nitride on the core. A layer of a cladding metal may be bonded to the aluminum nitride. The composition also may include particles of cubic boron nitride and/or particles of metal alloy blended with the grains of silicon carbide.

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Gerlikon, Switzerland

Richard Karl Schmid