General Electric Company

Other

Thomas Edward Mantkowski

Nripendra Nath Das

Raymond William Heidorn

Bhupendra Kumar Gupta

Jeffrey Allen Conner

Patricia A Charles

Jackie Lee King

Roger Dale Wustman

Jonathan Philip Clarke

Floyd A Swigert

Robert William Bruce

Jeffrey Allan Pfaendtner

Joshua L Miller

Antonio Frank Maricocchi

Shawn Michael Pearson

Stephen Mark Molter

Eric J Whitney

Ernest B Cooper, Jr

Keith Humphries Betscher

John M Crow

Timothy Lane Norris

W Michael Gmerek, Jr

David G W Fargher

Anthony Wayne Reynolds

William E Brummett, Ii

Meghan Meredith Olds

John Maynard Crow

A system and methods for applying a ceramic coating to a component that includes first applying a coating material to a first portion of a component. A removal agent is then applied to a second portion of the component that has an overspray byproduct thereon, and then the ceramic coating material is applied to at least the second portion of the component.

Process for depositing a ceramic coating and product formed thereof

A process of depositing a ceramic coating on an airfoil component and the component formed thereby is provided. The process includes depositing a bond coat on an airfoil component including on a trailing edge region thereof that defines a trailing edge of the airfoil component, within holes located within the trailing edge region and spaced apart from the trailing edge, and on lands located within the trailing edge region and between the holes. A ceramic coating is then deposited on the bond coat including on the trailing edge region of the airfoil component, within the holes located within the trailing edge region, and on the lands between the holes. The ceramic coating within the holes is selectively removed without completely removing the ceramic coating on the trailing edge region and the lands between the holes.

Process for selectively producing thermal barrier coatings on turbine hardware

Methods and apparatuses by which an oxidized metallic surface can be prepared for a subsequent repair operation without excessive removal of parent metal material. At least one gas is supplied to a limited portion of a metallic surface of a component, and the limited portion is locally heated in the presence of the gas to a treatment temperature sufficient to cause the gas or a gas that forms therefrom to chemically remove oxides from the limited portion of the metallic surface. At least a second portion of the metallic surface is not locally heated to the treatment temperature.

Localized cleaning process and apparatus therefor

A fluoride ion cleaning method includes generating hydrogen fluoride (HF) gas in-situ in a cleaning retort; contacting a part in need of cleaning with the generated HF gas; scrubbing an initial effluent stream in-situ to substantially remove residual HF gas therefrom; and passing the scrubbed effluent gas stream out of the cleaning retort. In an exemplary method, a liquid or gaseous halogenated feedstock is introduced into a cleaning retort; hydrogen gas is introduced into the cleaning retort, HF gas is generated by a reaction of the feedstock with hydrogen gas at a sufficient temperature. In an exemplary method, only HF gas generated in-situ or reconstituted in-situ is utilized in the cleaning process.

Fluoride ion cleaning method

A method and apparatus for controlling the thickness of a coating deposited on internal passages of a component. The coating is a diffusion coating, preferably a diffusion aluminide coating, deposited by a vapor phase process that entails placing a component within a coating chamber so that first and second conduits fluidically communicate with first and second openings in the component. The component is heated within the coating chamber, at least one reactive vapor is generated within the coating chamber, and a carrier gas is delivered through the first conduit to force the reactive vapor to enter the internal passages through the first opening in the component and exit through the second opening. Flow of the carrier gas is then reversed so that the carrier gas is then delivered through the second conduit to force the reactive vapor to enter the internal passages through the second opening and exit through the first opening.

Method and apparatus for controlling diffusion coating of internal passages

A method includes shrink fitting a ring member about a railroad wheel body and metallurically bonding the ring member to the railroad wheel body. A wheel assembly includes an inner portion obtained from a worn railroad wheel, a ring member disposed about the inner portion, and suitable electroplating material disposed on at least one of the faying surfaces. The wheel assembly may be heated under suitable conditions to provide diffusion bonding across interfacing faying surfaces to produce an integral wheel structure. Appropriate quenching, tempering, and finishing processes may be utilized to obtain desired properties. An article formed thereby includes an inner body portion obtained from a worn railroad wheel and a metallurically bonded outer circumferential portion. The outer portion may comprise a composition selected for desired wear characteristics.

Method for repair of rail wheels

A bond coat process for thermal barrier coatings. The method includes, after cleaning and masking the external surface of the substrate, first applying a layer of NiCrZr alloy to the external surface of the substrate using a sputter coat or other suitable process. Aluminum is then applied to the substrate, using either a vapor phase aluminization (VPA) or chemical vapor deposition (CVD) process, wherein aluminum diffuses into the NiCrZr alloy layer wherein a diffusion layer is formed by the aluminum with the substrate material on the internal surface of the substrate. The coated substrate may then be subjected to a heat treatment in a protective atmosphere to further allow diffusion of the aluminide into the NiAlCrZr diffusion layer. The substantially Al outer layers of the NiAlCrZr diffusion layer, and the diffusion aluminide layer, will provide an aluminum source for the surface, which will oxidize to form a tightly adherent aluminum scale. The diffusion aluminide layer and the high Al portion of the NiAlCrZr diffusion layer will also function as a source of aluminum which will provide a reservoir to heal the alumina scale during operation.

Bond coat process for thermal barrier coating

Apparatus and method to improve vapor phase diffusion coating of articles. The apparatus provides a barrier to segregate the portion of the article requiring coating from the portion of the article not requiring coating. The fixture is reusable, being unaffected by the coating gases. The fixture reduces the exposure of the coating gases with the portion of the article not requiring coating. By use of an optional seal, the portion of the article not requiring coating can be isolated from the coating gases.

Process for masking turbine components during vapor phase diffusion coating

Process for selectively masking turbine components during vapor phase diffusion coating

A thermal barrier coating (TBC) system and method for forming the TBC system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The TBC system exhibits improved spallation resistance as a result of having a bond coat formed to contain a dispersion of oxide particles in its outer surface region. A method for preferentially entrapping oxide particles in a bond coat entails depositing the oxide particles on the surface of the component prior to forming the bond coat, which may be a diffusion aluminide or an aluminized overlay coating. Deposition of the bond coat causes the oxide particles to become dispersed in the outer surface region of the bond coat. A particular feature of this invention is the ability to preferentially entrap oxides of elements that are not present in the bond coat or a substrate region of the component on which the bond coat is formed.

Thermal barrier coating system with improved bond coat

A thermal barrier coating system and a method for forming the coating system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The coating system includes a diffusion aluminide bond coat whose oxide growth rate is significantly reduced to improve the spallation resistance of a thermal barrier layer by forming the bond coat to include a dispersion of aluminum, chromium, nickel, cobalt and/or platinum group metal oxides. The oxides preferably constitute about 5 to about 20 volume percent of the bond coat. A preferred method of forming the bond coat is to initiate a diffusion aluminizing process in the absence of oxygen to deposit a base layer of diffusion aluminide, and then intermittently introduce an oxygen-containing gas into the diffusion aluminizing process to form within the bond coat the desired dispersion of oxides. Thereafter, a ceramic layer is deposited on the bond coat to form a thermal barrier coating.

Method of forming a diffusion aluminide coating

A process for forming a diffusion aluminide coating on a substrate, such as a component for a gas turbine engine. The process generally entails placing the substrate in a suitable coating chamber, flowing an inert or reducing gas into and through the coating chamber, and then aluminizing the substrate using an aluminizing technique with a substantially constant aluminum activity, such as a vapor phase deposition process. During the aluminizing process, the amount of unreacted aluminum within the coating chamber is controlled by altering the flow rate of the gas through the coating chamber so that a portion of the unreacted aluminum is swept from the coating chamber by the gas. The amount of unreacted aluminum swept from the coating chamber is regulated by metering the gas flow rate in order to control the aluminizing rate and aluminum content of the resulting aluminide coating.

Method of controlling thickness and aluminum content of a diffusion aluminide coating

A process for forming a diffusion aluminide-hafnide coating on an article, such as a component for a gas turbine engine. The process is a vapor phase process that generally entails placing the article in a coating chamber containing a halide activator and at least one donor material. The donor material collectively consists essentially of at least 0.5 weight percent hafnium and at least 20 weight percent aluminum with the balance being chromium and/or cobalt.

Method of forming a diffusion aluminide-hafnide coating

A process for forming a diffusion aluminide coating on an article, such as a component for a gas turbine engine. The process is a vapor phase process that generally entails placing the article in a coating chamber containing an aluminum donor material, without any halide carrier or inert filler present. The aluminum donor material consists essentially of about 20 to about 70 weight percent aluminum, with the balance being chromium or cobalt. While the article is held out of contact with the donor material, coating is initiated in an inert or reducing atmosphere by heating the article and the donor material to vaporize the aluminum constituent of the donor material, which then condenses on the surface of the article and diffuses into the surface to form a diffusion aluminide coating on the article.

Vapor phase diffusion aluminide process

A process for reclaiming aluminum alloy donor from a vapor phase deposition process used to form a diffusion aluminide coating on a component, such as the high-temperature superalloy components of gas turbine engines. The process generally entails recycling a particulate aluminum alloy donor material that, as a result of having been used as the donor material for depositing a diffusion aluminide coating on an article by vapor phase deposition, particles of the donor material comprise an aluminum alloy core encased in an aluminum-depleted shell. The process generally entails tumbling the donor material in a manner that removes the aluminum-depleted shell, followed by sieving the donor material to remove shell fragments and undersized particles.

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Madeira, OH, United States of America

Thomas Edward Mantkowski