General Electric Company

Stephen Daniel Graham

John Herbert Wood

Cyril Gerard Beck

Warren Tan King

Martin Lewis Smith

Robert Leighton Ling

Michael Wayne Wallace

Mark Francis DeSoi

A family of castable and weldable nickel-base alloys that exhibit a desirable balance of strength and resistance to corrosion and oxidation suitable for gas turbine engine applications. A first alloy consists essentially of, by weight, 1 8% to 20% cobalt, 22.2% to 22.8% chromium, 1.8% to 2.2% tungsten, greater than 1.5% to 2.3% aluminum, 1.6% to 2.4% titanium, where the sum of aluminum and titanium is 2.8% to 4.4%, 0.7% to 0.9% columbium, 0.9% to 1.9% tantalum, 0.003% to 0.009% boron, 0.002% to 0.02% zirconium, 0.05% to 0.10% carbon, with the balance essentially nickel and incidental impurities. A second alloy consists essentially of, by weight, 5% to 8% cobalt, 22.2% to 22.8% chromium, 1.8% to 2.2% tungsten, 1.2% to 2.3% aluminum, 1.6% to 2.4% titanium, where the sum of aluminum and titanium is 2.8% to 4.4%, 0.7% to 0.9% columbium, 0.9% to 1.9% tantalum, 0.003% to 0.009% boron, 0.002% to 0.02% zirconium, 0.05% to 0.10% carbon, with the balance essentially nickel and incidental impurities.

Nickel-base alloy

Castable and weldable nickel-base alloys that exhibit a desirable balance of strength and resistance to corrosion and oxidation suitable for gas turbine engine applications. The alloy contains, by weight, about 10% to about 25% cobalt, about 20% to about 28% chromium, about 1% to about 3% tungsten, about 1.6% to about 3.8% aluminum, about 0.4% to about 1.5% titanium, where the sum of aluminum and titanium is about 1.8% to about 5.0%, about 0.5% to about 1.5% columbium, 0.5% to about 1.5% tantalum, about 0.001% to about 0.025% boron, about 0.05% maximum zirconium, about 0.02% to about 0.15% carbon, with the balance essentially nickel and incidental impurities. The alloy may more preferably contain about 2.8% to about 3.8% aluminum where the sum of aluminum and titanium is about 3.0% to about 5.0%, or about 1.6% to about 2.8% aluminum, where the sum of aluminum and titanium is about 1.8% to about 4.3%.

An aluminiding process that enables the cooling holes of an air-cooled component, such as a hot gas path component of a gas turbine engine, to be machined and then aluminized after all external surface coatings have been deposited. The aluminide coating is deposited using a slurry process capable of forming the aluminide coating on the component without damaging an existing ceramic coating on the component. The process involves applying an activator-free slurry containing aluminum particles that, when the component is sufficiently heated, melt and diffuse into the component surface to form the diffusion aluminide coating.

Aluminide coating process

A process for applying a vertically cracked ceramic thermal barrier coating to a machine component includes a.) applying a plurality of layers of the ceramic thermal barrier coating on the component, utilizing a nozzle at a first distance from the component; b.) applying an additional sacrificial outer layer of the ceramic thermal barrier coating of the same chemical composition as the plurality of layers on the component, with the nozzle at a second distance from the component, greater than the first distance; and c) removing at least some of the outer layers to achieve thickness and surface roughness specifications.

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Stephen Daniel Graham