General Electric Company

Other

Robert Edward Schafrik

Ramgopal Darolia

Ching-Pang Lee

Eric Allen Ott

Jon Raymond Groh

Melvin Robert Jackson

Joseph David Rigney

Ji-Cheng Zhao

Matthew Bernard Buczek

Daniel D Krueger

Bernard Patrick Bewlay

Bangalore Aswatha Nagaraj

John Frederick Ackerman

Andrew Philip Woodfield

Pazhayannur Ramanathan Subramanian

Michael Francis Xavier Gigliotti

Mark Daniel Gorman

David Paul Mourer

Liang Jiang

Steven R LeClair

Kenneth Rees Bain

John Francis Maguire

William C Fitzgerald

A compositionally graded gas turbine disk is made by preparing a rotationally symmetric radially inner segment of a gas turbine disk preform, rotating the inner segment about a central axis, spray applying a radially outer-segment material onto the radially inner segment as it rotates about the central axis, preferably achieving a gradual transition in composition, and thereafter further processing the gas turbine disk preform to produce the compositionally graded gas turbine disk.

Method for making a compositionally graded gas turbine disk

An article is prepared by furnishing a plurality of powder particle substrates made of a substrate metal, providing a nonmetallic precursor of a metallic coating material, wherein the metallic coating material comprises an alloying element that is thermophysically melt incompatible with the substrate metal, contacting the powder particle substrates with the nonmetallic precursor, chemically reducing the nonmetallic precursor to form coated powder particles comprising the powder particle substrates having a surface-enriched layer of the metallic coating material thereon without melting the powder particle substrates, and processing the coated powder particles to form the article, without melting the powder particle substrates.

Article prepared by depositing an alloying element on powder particles, and making the article from the particles

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

A compositionally graded gas turbine disk is made by placing a cylindrically symmetric slip case concentrically into an interior of a cylindrically symmetric outer container. A first nickel-base superalloy powder is loaded into a radially inner first portion of the interior and a second nickel-base superalloy powder is loaded into a radially outer second portion of the interior. The slip case is removed so that the first nickel-base superalloy powder and the second nickel-base superalloy powder contact in the transition region and form a non-compacted powder mass. The non-compacted powder mass is processed into a gas turbine disk, typically by compacting the non-compacted powder mass to form a compacted powder mass, and thereafter heat treating the compacted powder mass.

A coating and coating process for incorporating surface features on an air-cooled substrate surface of a component for the purpose of promoting heat transfer from the component. The coating process generally comprises depositing a first metallic coating material on the surface of the component using a first set of coating conditions to form a first environmental coating layer, and then depositing a second metallic coating material using a second set of coating conditions that differ from the first set, such that an outer environmental coating layer is formed having raised surface features that cause the surface of the outer environmental coating layer to be rougher than the surface of the first environmental coating layer.

Coating and coating process incorporating raised surface features for an air-cooled surface

One exemplary embodiment of a turbine component (which may be a blade) comprises a substrate comprising a silicide-based material, a plurality of through holes disposed in the substrate, the holes being configured to receive an airflow, a silicide coating disposed at the surfaces of the substrate and the through holes, and a thermal barrier coating disposed at the silicide coating. In another exemplary embodiment the silicide coating may be replaced by a Laves phase-containing layer. In still another exemplary embodiment the silicide coating may be replaced by a diffusion barrier layer disposed at a surface of the substrate and a platinum group metal layer disposed at the diffusion barrier layer. One exemplary embodiment of a blade may comprise an airfoil comprising a silicide-based material and through holes disposed therein, a cooling plenum disposed in the airfoil, and a base configured to receive the airfoil in a dovetail fit, the base comprising a superalloy.

Turbine blade for extreme temperature conditions

A non-destructive method of detecting subsurface defects in thermal barrier coatings applied to gas turbine engine components is provided. In an exemplary embodiment, the method includes positioning a evanescent microwave microscope probe adjacent a turbine component surface coated with a thermal barrier coating, and scanning the thermal barrier coating by moving at least one of the evanescent microwave microscope probe and the component surface in relation to one another in an x-y plane while maintaining a predetermined distance between the probe and the thermal barrier coating constant.

Non-destructive evaluation of thermal barrier coatings in gas turbine engines

A coated article having a high resistance to particle-impact damage has a substrate, and a layered coating overlying the substrate. The layered coating includes a substantially continuous quasicrystalline layer, and a substantially continuous ductile metallic layer in facing contact with the quasicrystalline layer. The coated article is preferably used in applications where it is subjected to particle-impact conditions.

Coated article having a quasicrystalline-ductile metal layered coating with high particle-impact damage resistance, and its preparation and use

A coated article having a high resistance to wear damage has a substrate, and a layered coating overlying the substrate. The layered coating includes a ductile metallic layer overlying and in facing contact with the substrate, and a protective layer overlying and in facing contact with the ductile metallic layer and including a mixture of a quasicrystalline metallic phase and a non-quasicrystalline ductile phase. The coated article is preferably used in applications where it is subjected to wear conditions.

Coated article having a quasicrystalline-ductile metal layered coating with high wear resistance, and its preparation and use

An article for use in a hot gas path of a gas turbine assembly, a metallic skin for such an article, and a method for making such an article are presented with, for example, the article comprising a spar, the spar providing mechanical support for the article and comprising a cooling fluid delivery system, a top end, and a bottom end; a standoff structure attached to the spar, the standoff structure comprising a plurality of spacing elements in a spaced-apart relation to each other, the spacing elements having first ends adjacent to the spar and second ends opposite to the first ends; a skin conformally surrounding the spar and the standoff structure, the skin comprising a top end and a bottom end, wherein the standoff structure separates the spar and the skin, wherein the plurality of spacing elements is disposed with an inner surface of the skin adjacent to the second ends of the spacing elements to form a plurality of plena between the spar and the skin, the plena in fluid communication with the cooling fluid delivery system, the skin comprising at least one metal selected from the group consisting of Rh, Pd, and Pt; and a base connecting the bottom end of the spar and the bottom end of the skin.

Hybrid high temperature articles and method of making

An actively cooled TBC bond coat wherein active convection cooling is provided through micro channels inside or adjacent to a bond coat layer applied to a substrate. The micro channels communicate directly with at least one cooling fluid supply contained within a turbine engine component, thereby providing direct and efficient cooling for the bond coat layer. Because the substrate is covered with an actively cooled bond coat layer, it will reduce the cooling requirement for the substrate, thus allowing the engine to run at higher operating temperature without the need for additional cooling air, achieving a better engine performance. In one form, the component includes a substrate having at least one substrate channel with a first and second end. At least one micro channel is in fluid communication with a plenum which in turn is in fluid communication with at least one substrate channel through an exit orifice in the substrate channel which is at a first end of the substrate channel. A second end of the substrate channel is in communication with a cooling fluid supply, for example, cooling circuits contained within the turbine engine component. The micro channel is located between the substrate surface and the outer gas flow path surface of the component.

Directly cooled thermal barrier coating system

A cooling system for cooling of the flow path surface region of an engine component used in a gas turbine engine and a method for making a system for cooling of the flow path surface region of an engine component used in a gas turbine engine. The method comprises the steps of channeling apertures in a substrate to a diameter of about 0.0005&Prime; to about 0.02&Prime; to allow passage of cooling fluid from a cooling fluid source; applying a bond coat of about 0.0005&Prime; to about 0.005&Prime; in thickness to the substrate such that the bond coat partially fills the channels; applying a porous inner TBC layer of at least about 0.01&Prime; in thickness to the bond coat, such that the TBC fills the channels; applying an intermediate ceramic layer that is more dense than the inner TBC layer on top of the porous TBC; applying an outer TBC layer over the intermediate layer; and, passing cooling fluid from a cooling fluid source through the channel into the porous TBC. The density of thc outer TBC layer can be varied as needed to achieve desired cooling objectives. Because the channel exit is filled with porous TBC material, cooling fluid flows through the porous passageways into the inner TBC layer. Although the passageways provide a plurality of tortuous routes, the increased density of the TBC in the intermediate layer provides a resistance to flow of the cooling fluid and effectively causes the cooling fluid to more efficiently spread through the TBC in the inner layer before exiting at the outer surface.

Method for cooling engine components using multi-layer barrier coating

The present invention provides a process for forming active convection cooling micro channels within or adjacent to a bond coat layer applied to a turbine high pressure turbine airfoil. When placed adjacent or within a porous TBC, the micro channels additionally provide transpiration cooling through the porous TBC. The micro channels communicate directly with at least one cooling circuit contained within the airfoil from which they receive cooling air, thereby providing direct and efficient cooling for the bond coat layer. Because the substrate includes an actively cooled flow path surface region that can reduce the cooling requirement for the substrate, the engine can run at a higher firing temperature without the need for additional cooling air, achieving a better, more efficient engine performance. In one embodiment, a metallic bond coat is applied to an airfoil. The bond coat is grooved such that the grooves are structured, with at least one structured micro groove communicating with at least one cooling fluid supply contained within the airfoil. A TBC layer is applied over the structured grooves, resulting in the formation of hollow micro channels for the transport of the cooling fluid due to self-shadowing. In different embodiments, the location of the structured grooves, hence, the resulting micro channels are placed within the airfoil substrate at the substrate/bond coat interface or within the TBC layer.

Process for forming micro cooling channels inside a thermal barrier coating system without masking material

A process for creating microgrooves within or adjacent to a TBC layer applied to a gas turbine engine component such as a blade or vane. The process includes the steps of applying a bond coat to the surface of the substrate. A wire mesh is placed a predetermined distance above the bond coat surface. With the wire mesh in position, about 0.002 inches of an inner TBC is applied over the bond coat. The wire in the wire mesh causes a shadow effect as the TBC is applied, so that there are variations in the thickness of the applied TBC, forming micro channels. The wire mesh is removed and an additional outer TBC layer is applied over the inner TBC layer, and the variations in thickness are bridged by the continued deposition of the columnar TBC over the inner TBC layer, forming the microgrooves.

Growing community of inventors

Cincinnati, OH, United States of America

Robert Edward Schafrik