Honeywell International Inc.

Alliedsignal Inc.

United Technologies Corporation

United States of America As Represented by the Secretary of the Air Force

Other

Thomas E Strangman

Derek Raybould

Chien-Wei Li

Bjoern Schenk

Dave Narasimhan

Mark C Morris

Patricia A Solfest

Malak Fouad Malak

Steve Halfmann

Paul Chipko

Alexander S Kozlov

Margaret M Floyd

Keith R Karasek

Paul J Mravcak

Alex Kozlov

James L Schienle

William C Baker

Robert J Keiser

Jeffrey P Armstrong

Harry Lester Kington

Devlin M Gualtieri

David K Jan

Paul Yankowich

Vladimir K Tolpygo

Derek Anthony Rice

Milton Ortiz

Christopher Zollars

Duane L Ruckle

Lee Poandl

Siu-Ching D Lui

Craig A Wilson

George W Wolfmeyer

William E Fischer

Christian Delacruz

Udo Schuelke

Chen-Wei Li

Hongda Cai

Michael L Easley

Paul A Chipko

Steven J Vonk

James S Perron

Svetlana Kozlova, Legal Representative

Derek A Rice

Methods are provided that include depositing a nickel-base superalloy powder including gamma nickel solid solution and gamma prime (NiAl) solid solution phases onto a seed crystal having a predetermined primary orientation, fully melting the powder and a portion of the seed crystal at a superliquidus temperature to form an initial layer having the predetermined primary orientation, heat treating the layer at subsolvus temperatures to precipitate gamma prime solid solution phase particles, depositing additional powder over the layer, melting the deposited powder and a portion of the initial layer at a superliquidus temperature to form a successive layer having the predetermined primary orientation, heat treating the layer at a subsolvus temperature to precipitate gamma prime solid solution phase particles, and repeating depositing additional powder, melting the additional powder and the portion of the successive layer at the superliquidus temperature, and heat treating the successive layer at a subsolvus temperature.

Methods of fabricating turbine engine components

Exemplary embodiments of the invention provide barrier coated substrates and methods of coating a substrate with a barrier coating derived from sol gels. An example includes a barrier coated aerospace component that is subject to hot salt corrosion during use. The barrier coating is derived from oxidation of a coating composition that includes at least one sol gel. The barrier coating resists hot salt corrosion for an incubation period of such duration that an uncoated superalloy substrate under the same conditions would suffer corrosion to a depth of about 2.0 mils. Methods of applying the barrier coating include the steps of selecting a first liquid sol gel and wetting surfaces of the superalloy substrate with the selected first liquid sol gel. The wetted surfaces of the superalloy substrate are subjected to heat treatment. The heat treatment includes sintering of sol gel to oxide to produce a barrier coating.

Protective barrier coatings

A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.

Thermal barrier coating resistant to penetration by environmental contaminants

Turbine components are provided. In an embodiment, by way of example, a hub and a ring are included. The hub comprises a first material. The ring is bonded to the hub. The ring comprises a plurality of arc segments forming a ring, each arc segment comprising a second material comprising a single crystal superalloy material having a predetermined primary orientation and a predetermined secondary orientation, each predetermined primary orientation of each arc segment being substantially equal, and each predetermined secondary orientation of each arc segment being substantially equal, each arc segment adjacent another arc segment, and the adjacent arc segments having a predetermined crystallographic mismatch therebetween. Methods of manufacturing are also provided.

Turbine components and methods of manufacturing turbine components

According to a method for forming a coating system on a turbine engine component substrate that comprises a nickel-based superalloy substrate having at least one refractory metal included therein, a nickel-based layer is formed on the substrate, the nickel-based layer comprising at least one active material selected from the group consisting of elemental silicon and a silicon compound. The at least one active material is then diffused into the substrate. An yttrium-modified platinum aluminide bond coating, or a MCrAlX bond coating, may be then formed over the active material-modified nickel-based layer.

Method of forming bond coating for a thermal barrier coating

A dual alloy turbine rotor is provided and includes an integrally formed blade ring and a disk. The blade ring is made of a first alloy and includes a ring portion and a plurality of airfoils extending therefrom, where the ring portion includes an inner surface, and each airfoil includes an internal cavity formed therein. The disk is made of a second alloy and may have a beveled outer peripheral surface. The disk is disposed within the ring portion such that the disk outer peripheral surface contacts at least a portion of the ring portion inner surface. Methods of manufacturing the turbine rotor are also provided.

Multi-alloy turbine rotors and methods of manufacturing the rotors

An article having a thermal barrier coating includes a superalloy substrate having a columnar grained ceramic coat formed thereon. The ceramic coat includes a nanolaminate region comprising repeating layers of ceramic material with each layer being less than 500 nm in thickness, with dispersions of metal oxide doping material situated between each of the layers. The ceramic coat further includes a non-doped region having a thickness greater than 500 nm adjacent to the nanolaminate region, the non-doped region including one layer or a plurality of adjacent layers of ceramic material without dispersions of metal oxide doping material situated between each of the layers. In one embodiment, and by way of example only, a bond coat is formed between the substrate and the columnar grained ceramic coat. According to another embodiment, the superalloy substrate forms an adherent alumina scale, and no bond coat is necessary.

Nanolaminate thermal barrier coatings

A protective coating for a component comprising a ceramic based substrate, and methods for protecting the component, the protective coating adapted for withstanding repeated thermal cycling. The substrate may comprise silicon nitride or silicon carbide, and the protective coating may comprise at least one tantalate of scandium, yttrium, or a rare earth element. The protective coating may further comprise one or more metal oxides. The coating protects the substrate from combustion gases in the high temperature turbine engine environment. The coating may be multi-layered and exhibits strong bonding to Si-based substrate materials and composites.

Protective coating for ceramic components

Platinum containing coatings for corrosion and oxidation protection of a substrate, and platinum electrodeposition methods for coating a substrate. The coating may comprise platinum and at least one supplementary constituent, and the method may involve co-electrodeposition of platinum and the supplementary constituent from a single electrolyte composition. The supplementary constituent may comprise chromium, an oxidation protective reactive element, or an alloy of chromium with a reactive element. Components protected by such coatings are also disclosed.

Platinum aluminide coating and method thereof

A diffuser particle separator may be integrated into a gas turbine engine to remove corrosive dust and salt particles from the engine's core air flow. The air flow may pass over a series of particle accumulator entrance orifices, trapping particles in a particle accumulator while allowing the air flow to continue unimpeded. Since dust deposits may become molten at high temperatures, removal of dust from the core and secondary airflow may be critical for long-life superalloy and ceramic components, particularly those with small diameter air-cooling holes and thermal barrier coatings.

Diffuser particle separator

Methods and apparatus to make multilayer thermal barrier coatings for superalloy substrates such as turbine blades or vanes are disclosed. The methods produce non-homogeneous, nanometer-size, successive layers and a non-homogeneous interfacial layer without the use of baffles. Methods are also disclosed to use a lower cost metallic source and an oxygen bleed to create alumina or tantalum oxide vapor, to use a tantalum oxide or an alumina ingot and a low pressure inert gas feed to direct the vapor clouds, to use pulsed evaporation from a secondary vapor source to create non-homogeneous multilayer coating on non-rotated substrates, to use an electric bias to direct the vapor clouds, and to use a mechanical system to direct the vapor clouds or move and position the article to be coated in the clouds.

Apparatus to make nanolaminate thermal barrier coatings

A turbine blade tip and shroud clearance control coating system comprising an abrasive blade tip coating and an abradable shroud coating are provided. The abrasive layer may comprise abrasive particles of cubic zirconia, cubic hafnia or mixtures thereof, and the abradable layer may be a nanolaminate thermal barrier coating that is softer than the abrasive layer. The invention further provides an alternate coating system comprising an abradable blade tip coating and an abrasive shroud coating.

Turbine blade tip and shroud clearance control coating system

A turbine blade tip and shroud clearance control coating system comprising a dense abrasive blade tip layer and an abradable shroud layer are provided. The dense abrasive coating may comprise cubic zirconia, hafnia or mixtures thereof and the abradable layer may be a nanolaminate thermal barrier coating that is softer than the dense abrasive layer.

A protective barrier coating system including a diffusion barrier coating and an oxidation barrier coating and method for use in protecting silicon-based ceramic turbine engine components. A complete barrier coating system includes a thermal barrier coating of stabilized zirconia and an environmental barrier coating of an alloyed tantalum oxide. The oxidation barrier coating includes a layer of metallic silicates formed on a substrate of silicon nitride or silicon carbide to be protected. The oxidation barrier coating can include silicates of scandium, ytterbia or yttrium. The oxidation barrier coating may also include an inner layer of SiONbetween the diffusion barrier and the metallic silicate layer. The oxidation barrier coating can be applied to the substrate by spraying, slurry dipping and sintering, by a sol-gel process followed by sintering, by plasma spray, or by electron beam-physical vapor deposition. The diffusion layer of essentially pure SiNcan be applied to the substrate to prevent the migration of damaging cations from the protective layers to the substrate and is preferably formed by chemical vapor deposition. A method for protecting silicon based substrates can comprise a step of forming an oxidation barrier coating on a substrate, where a step of forming the oxidation barrier includes a step of sintering the oxidation barrier and substrate in a wet gas containing hydrogen.

Oxidation barrier coatings for silicon based ceramics

Growing community of inventors

Phoenix, AZ, United States of America

Thomas E Strangman