An optimized metallic thermal spray coating able to achieve a suitable surface finish such that it slides against a hydraulic seal without damaging the surface of the hydraulic seal or causing hydraulic fluid to leak between the two sliding surfaces. The optimized metallic thermal spray coating can achieve a surface finish which has a combination of roughness characteristics consisting of an arithmetical mean roughness, a maximum profile peak height, a mean roughness depth designated, skewness, and a roughness relative material ratio, each of which is within well-defined upper limits and/or ranges.
An optimized metallic thermal spray coating able to achieve a suitable surface finish such that it slides against a hydraulic seal without damaging the surface of the hydraulic seal or causing hydraulic fluid to leak between the two sliding surfaces. The optimized metallic thermal spray coating can achieve a surface finish which has a combination of roughness characteristics consisting of an arithmetical mean roughness, a maximum profile peak height, a mean roughness depth designated, skewness, and a roughness relative material ratio, each of which is within well-defined upper limits and/or ranges.
A modified ternary Zr-Ta-Y oxide system is provided having a larger non- transformable, tetragonal phase that enables thermal barrier materials with improved properties of low thermal conductivity, higher sinter resistance, higher phase stability, and higher toughness to be created.
C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
4.
THERMAL BARRIER MATERIAL EXHIBITING MANUFACTURABILITY, HIGH TOUGHNESS AND LOW THERMAL CONDUCTIVITY
A modified ternary Zr—Ta—Y oxide system is provided having a larger non-transformable, tetragonal phase that enables thermal barrier materials with improved properties of low thermal conductivity, higher sinter resistance, higher phase stability, and higher toughness to be created.
C04B 35/48 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
C23C 14/30 - Vacuum evaporation by wave energy or particle radiation by electron bombardment
5.
METHODS FOR CREATING A NICKEL STRIKE LAYER AND NICKEL ELECTROLYTIC BONDCOAT ONTO A NON-CONDUCTIVE CARBON FIBER COMPOSITE SURFACE AND THE COATING SYSTEM DERIVED THEREFROM
Novel methods for activating and electroplating a non-conductive carbon fiber composite part are provided. An exposed surface of the CFC part is mechanically activated followed by creating a relatively thin nickel strike layer in a controlled electrolytic process. A relatively thicker electrolytic nickel layer is deposited over the strike layer. The electrolytic nickel strike layer and electrolytic nickel layer serve as the foundation to enable deposition of any suitable erosion resistant coating thereon.
C25D 5/14 - Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium two or more layers being of nickel or chromium, e.g. duplex or triplex layers
C25D 5/56 - Electroplating of non-metallic surfaces of plastics
C25D 3/12 - ElectroplatingBaths therefor from solutions of nickel or cobalt
METHODS FOR CREATING A NICKEL STRIKE LAYER AND NICKEL ELECTROLYTIC BONDCOAT ONTO A NON-CONDUCTIVE CARBON FIBER COMPOSITE SURFACE AND THE COATING SYSTEM DERIVED THEREFROM
Novel methods for activating and electroplating a non-conductive carbon fiber composite part are provided. An exposed surface of the CFC part is mechanically activated followed by creating a relatively thin nickel strike layer in a controlled electrolytic process. A relatively thicker electrolytic nickel layer is deposited over the strike layer. The electrolytic nickel strike layer and electrolytic nickel layer serve as the foundation to enable deposition of any suitable erosion resistant coating thereon.
Novel multilayer aqueous slurries and coatings for hot corrosion protection of substrates are provided that exhibit improved resistance to type II hot corrosion while also being hexavalent chromium free. The compositions represent a notable departure and performance improvement from conventional coating systems utilized for hot corrosion protection.
Novel multilayer aqueous slurries and coatings for hot corrosion protection of substrates are provided that exhibit improved resistance to type II hot corrosion while also being hexavalent chromium free. The compositions represent a notable departure and performance improvement from conventional coating systems utilized for hot corrosion protection.
Novel alumina-forming and multi-element materials are provided that can enable operation of gas turbine components and other components exposed to high temperature applications. The formulations represent a notable departure and improvement from conventional materials such as MCrAlY.
C22C 30/00 - Alloys containing less than 50% by weight of each constituent
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
Improved wear resistant coatings are provided based upon a novel abrasion resistance factor (R) for a given average size of abrasive fine particles. The improved wear resistant coatings exhibit minimal oxide content and minimal porosity, while exhibiting improved wear resistance and hardness. The improved wear resistant coatings are made from a composite material consisting of a hard phase and a metallic binder derived from powder particle sizes ranging from about 0.5 μm-30 μm as part of a modified thermal spray process.
The present invention generally relates to an atmospheric spray process for producing a controlled conical shrouded oxygen gas stream designed to intercept a plasma effluent stream to inject and mix oxygen with powder particles contained in the plasma effluent prior to the molten power particles entrained in the plasma effluent solidifying on a substrate.
B05B 7/08 - Spray pistolsApparatus for discharge with separate outlet orifices, e.g. to form parallel jets, to form intersecting jets
B05B 7/22 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating the material to be sprayed electrically, e.g. by arc
12.
Oxygen Interception for Air Plasma Spray Processes
The present invention generally relates to an atmospheric spray process for producing a controlled conical shrouded oxygen gas stream designed to intercept a plasma effluent stream to inject and mix oxygen with powder particles contained in the plasma effluent prior to the molten power particles entrained in the plasma effluent solidifying on a substrate.
A novel, modified cathode device having partially dome shaped portion with a cathode flat surface therealong has been created, whereby arc rotational movement is significantly improved over conventional cathode designs. A complimentary cathode holder with enhanced cooling features is provided to prevent overheating of the cathode tip. The end result is an improved, more versatile plasma arc spray gun that can run at elevated power and enthalpy levels without incurring thermal damage.
Hexavalent chromium-free slurry formulations which are suitable in the production of inorganic overlay coating systems are described. The formulations provide superior hot corrosion and high-temperature oxidation protection for superalloy substrates. A basecoat slurry and topcoat slurry are provided. The basecoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:P higher than about 1:3 with the incorporation of pigments of either metallic particles, or metal oxide particles, or both in combination. The topcoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of Al:P higher than about 1:3. An inorganic overlay coating formed on substrate made from the slurry formulation of present invention for hot corrosion protection on superalloy substrate against hot corrosion. Furthermore, a multilayer coating comprises a metallic bond coat and an inorganic overlay coating formed on superalloy substrate to further enhance high-temperature oxidation and hot corrosion protection.
A novel and improved thermal spray component having structurally enhanced roughened features on a wetted surface is provided. The structurally enhanced roughened features on the wetted surface enable a reduction in the accumulation of scale deposits and also improves coating property performance during operation of the thermal spray torch.
B05B 7/20 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating the material to be sprayed by flame or combustion
16.
Thin and texturized films having fully uniform coverage of a non-smooth surface derived from an additive overlaying process
This invention relates to a thin and texturized film that can be applied onto a non-smooth surface to improve hardness, corrosion resistance and wear resistance properties of the surface while maintaining the underlying profile of the non-smooth surface. An additive overlaying process can be employed to produce the thin and texturized film on the non-smooth surfaces without substantial alteration or degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The thin and texturized film fully covers the non-smooth in a uniform manner and maintains the surface profile.
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
B32B 3/30 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids characterised by a layer formed with recesses or projections, e.g. grooved, ribbed
C23C 4/04 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
C23C 4/067 - Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
Hexavalent chromium-free slurry formulations which are suitable in the production of inorganic overlay coating systems are described. The formulations provide superior hot corrosion and high-temperature oxidation protection for superalloy substrates. A basecoat slurry and topcoat slurry are provided. The basecoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of A1:P higher than about 1 :3 with the incorporation of pigments of either metallic particles, or metal oxide particles, or both in combination. The topcoat slurry includes an aluminum phosphate based aqueous solution having a molar ratio of A1:P higher than about 1 :3. An inorganic overlay coating formed on substrate made from the slurry formulation of present invention for hot corrosion protection on superalloy substrate against hot corrosion. Furthermore, a multilayer coating comprises a metallic bond coat and an inorganic overlay coating formed on superalloy substrate to further enhance high-temperature oxidation and hot corrosion protection.
C23C 14/00 - Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
C23C 22/73 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process
C23C 22/74 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process for obtaining burned-in conversion coatings
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
Hexavalent chromium-free slurries are provided that are capable of achieving a full cure at temperatures as low as 330 - 450 degrees F, thus making the coatings especially suitable for application on temperature sensitive base materials. The slurries are suitable in the production of protective coating systems formed by novel silicate-based basecoats that are sealed with novel phosphate-based topcoats. The coating systems exhibit acceptable corrosion and heat resistance and are capable of replacing traditional chromate-containing coating systems.
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C09D 1/02 - Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances alkali metal silicates
C09D 5/10 - Anti-corrosive paints containing metal dust
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
C04B 28/34 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
19.
MODIFIED CATHODE DEVICE AND HOLDER ASSEMBLY FOR PLASMA ARC SPRAY GUN
A novel, modified cathode device having partially dome shaped portion with a cathode flat surface therealong has been created, whereby arc rotational movement is significantly improved over conventional cathode designs. A complimentary cathode holder with enhanced cooling features is provided to prevent overheating of the cathode tip. The end result is an improved, more versatile plasma arc spray gun that can run at elevated power and enthalpy levels without incurring thermal damage.
Novel processes for forming improved coatings with increased crystallinity and density are provided. The process includes utilizing a laminar plasma plume to form the coatings without use of a separate auxiliary heating or post heat treatment step.
B05D 7/00 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
C04B 28/34 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
22.
Chromate-free ceramic coating compositions for hot corrosion protection of superalloy substrates
C04B 28/34 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
B05D 7/14 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
B05D 7/00 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
Hexavalent chromium-free slurries are provided that are capable of achieving a full cure at temperatures as low as 330-450 degrees F., thus making the coatings especially suitable for application on temperature sensitive base materials. The slurries are suitable in the production of protective coating systems formed by novel silicate-based basecoats that are sealed with novel phosphate-based topcoats. The coating systems exhibit acceptable corrosion and heat resistance and are capable of replacing traditional chromate-containing coating systems.
Polyurethane-based coatings which exhibit superior erosion and heat resistance combined with antifouling and chemical resistance that are useful for protection of metal components are provided. The coatings are characterized by enhanced particle erosion resistance and enhanced heat resistance and are derived from specific multicomponent slurry compositions.
Polyurethane-based coatings which exhibit superior erosion and heat resistance combined with antifouling and chemical resistance that are useful for protection of metal components are provided. The coatings are characterized by enhanced particle erosion resistance and enhanced heat resistance and are derived from specific multicomponent slurry compositions.
A composition based on a certain chromium-free silicate-based binder is described. The composition is an aqueous solution of lithium-doped potassium silicate in combination with an aluminum or aluminum alloy powder, zinc powder or a combination thereof. The coatings of the present invention_are capable of achieving a full cure at temperatures as low as 350-450 degrees F by the inclusion of a colloidal solution of a nano-sized ceria, thus making the coatings especially suitable for application on temperature sensitive base materials.
C23C 24/10 - Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
A composition based on a certain chromium-free silicate-based binder is described. The composition is an aqueous solution of lithium-doped potassium silicate in combination with an aluminum or aluminum alloy powder, zinc powder or a combination thereof. The coatings of the present invention are capable of achieving a full cure at temperatures as low as 350-450 degrees F. by the inclusion of a colloidal solution of a nano-sized ceria, thus making the coatings especially suitable for application on temperature sensitive base materials.
A fluid tight, fully-densified, coating is prepared by a High Velocity Oxygen Fuel ("HVOF") process that dilutes oxygen with an inert gas. The inert gas is premixed with oxygen prior to the oxygen entering a combustion chamber. The resultant flame temperature is lowered a controlled amount to eliminate, minimize or reduce oxidation of power feedstock that is injected into the thermal spray torch. The ability to reduce the flame temperature allows a relatively smaller particle feedstock to be deposited without significant oxidation. The dilution process creates an as-deposited fully-dense, fluid tight coating.
A fluid tight, fully-densified, coating is prepared by a High Velocity Oxygen Fuel (“HVOF”) process that dilutes oxygen with an inert gas. The inert gas is pre-mixed with oxygen prior to the oxygen entering a combustion chamber. The resultant flame temperature is lowered a controlled amount to eliminate, minimize or reduce oxidation of power feedstock that is injected into the thermal spray torch. The ability to reduce the flame temperature allows a relatively smaller particle feedstock to be deposited without significant oxidation. The dilution process creates an as-deposited fully-dense, fluid tight coating.
This invention relates to a thin and texturized film that can be applied onto a non-smooth surface to improve hardness, corrosion resistance and wear resistance properties of the surface while maintaining the underlying profile of the non-smooth surface. An additive overlaying process can be employed to produce the thin and texturized film on the non-smooth surfaces without substantial alteration or degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The thin and texturized film fully covers the non-smooth in a uniform manner and maintains the surface profile.
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
B21B 27/00 - RollsLubricating, cooling or heating rolls while in use
B32B 3/30 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids characterised by a layer formed with recesses or projections, e.g. grooved, ribbed
31.
FULLY DENSE, FLUID TIGHT AND LOW FRICTION COATING SYSTEMS FOR DYNAMICALLY ENGAGING LOAD BEARING SURFACES FOR HIGH PRESSURE HIGH TEMPERATURE APPLICATIONS
A fully-dense, fluid tight, low friction coating system is described that is characterized by fluid impermeability and a reduced coefficient of friction. The coating system includes a fully dense, fluid tight underlying layer; and a low friction layer. Unlike conventional materials requiring a sealant, the coating systems of the present invention achieves better fluid tightness and maintains said fluid tightness along one or more sealing surfaces at higher service temperatures and service pressures than previously attainable. The constituents of the fully-dense, fluid tight, low friction coating system are physically and chemically compatible so as to not adversely impact lubricity, wear resistance and corrosion resistance during the service life of a component coated with the fully-dense, fluid tight, low friction coating system.
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
A unique sequence of steps is provided to reduce contaminants along one or more surfaces and faces of gold evaporative sources without deleteriously impacting the structure of the gold evaporative sources. Edges are deburred; contaminants are successfully removed therealong; and surface smoothness is substantially retained. The resultant gold evaporative source is suitable for use in evaporative processes as a precursor to gold film deposition without the occurrence or a substantial reduction in the likelihood of spitting by virtue of significantly reduced levels of contaminants, in comparison to gold evaporative sources subject to a standard cleaning protocol.
C23C 14/56 - Apparatus specially adapted for continuous coatingArrangements for maintaining the vacuum, e.g. vacuum locks
B21C 1/00 - Manufacture of metal sheets, wire, rods, tubes or like semi-manufactured products by drawing
B24B 31/06 - Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work or the abrasive material is looseAccessories therefor involving oscillating or vibrating containers
B08B 3/10 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
B08B 3/12 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
B24B 39/00 - Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zoneAccessories therefor
33.
Methods of applying chromium diffusion coatings onto selective regions of a component
Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require diffusion-stop-off masking. Prior to or after a localized slurry chromizing process of the present invention, a layer of a platinum-group-metal (PGM) is applied to produce a PGM-modified chromium diffusion coating onto selected regions of a substrate. A second coating can be selectively applied onto other regions of the substrate.
C23C 16/06 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
C23C 10/14 - Solid state diffusion of only metal elements or silicon into metallic material surfaces using gases more than one element being diffused in one step
C23C 10/04 - Diffusion into selected surface areas, e.g. using masks
C23C 10/20 - Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions only one element being diffused
C23C 10/56 - Diffusion of at least chromium and at least aluminium
C23C 10/58 - Embedding in a powder mixture, i.e. pack cementation more than one element being diffused in more than one step
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
This invention relates to thermal spray coatings and processes onto non-smooth surfaces. The coating and processes can coat non-smooth surfaces without substantial degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The ability for coating fractional coverage to maintain the surface profile while maintaining wear resistance is unprecedented by conventional thermal spray processes.
C23C 4/073 - Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
C23C 4/00 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
C23C 4/067 - Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
C23C 4/14 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
This invention relates to a method and system for increasing the utilization of the supply of acetylene from two acetylene sources. The flow is provided at a substantially constant delivery pressure to a point of use, such as a customer point of use. A portable apparatus is configured to operably connect to each of the two acetylene sources simultaneously and during operation automatically provide flow from one of the acetylene sources through various valving and piping assembled onto the portable apparatus followed by supply to a customer point of use.
This invention relates to thermal spray coatings and processes onto non-smooth surfaces. The coating and processes can coat non-smooth surfaces without substantial degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The ability for coating fractional coverage to maintain the surface profile while maintaining wear resistance is unprecedented by conventional thermal spray processes
A novel dual layer mask formulation is provided. In particular, the mask has a unique composition that protects the integrity of an underlying chromide coating, prevents chromium depletion from the chromide coating and prevents a subsequent aluminide coating from being deposited thereon.
Novel slurry formulations and processes for forming improved protective coatings used in the hot section components of gas turbine engines are provided. The process includes a unique two-step deposition methodology whereby the required concentration of reactive element within an improved reactive element doped aluminide coating can be consistently produced in a reproducible manner.
C23C 22/73 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
C09D 5/10 - Anti-corrosive paints containing metal dust
C23C 10/58 - Embedding in a powder mixture, i.e. pack cementation more than one element being diffused in more than one step
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
39.
Mask formulation to prevent aluminizing onto the pre-existing chromide coating
A novel dual layer mask formulation is provided. In particular, the mask has a unique composition that protects the integrity of an underlying chromide coating, prevents chromium depletion from the chromide coating and prevents a subsequent aluminide coating from being deposited thereon.
B22F 7/00 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting
C23C 8/04 - Treatment of selected surface areas, e.g. using masks
C23C 8/08 - Solid state diffusion of only non-metal elements into metallic material surfacesChemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
C09D 1/00 - Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
C09D 5/10 - Anti-corrosive paints containing metal dust
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
C23C 10/04 - Diffusion into selected surface areas, e.g. using masks
C23C 10/08 - Solid state diffusion of only metal elements or silicon into metallic material surfaces using gases only one element being diffused
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
40.
SLURRY FORMULATIONS FOR FORMATION OF REACTIVE ELEMENT-DOPED ALUMINIDE COATINGS AND METHODS OF FORMING THE SAME
Novel slurry formulations and processes for forming improved protective coatings used in the hot section components of gas turbine engines are provided. The process includes a unique two-step deposition methodology whereby the required concentration of reactive element within an improved reactive element doped aluminide coating can be consistently produced in a reproducible manner.
C23C 10/58 - Embedding in a powder mixture, i.e. pack cementation more than one element being diffused in more than one step
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
A novel chromate-free multi-layer coating system composed of a lithium- doped potassium silicate binder based basecoat composition that is sealed with an aluminum phosphate-based top coat composition is described. The multi-layer coating system exhibits superior corrosion and heat oxidation resistance which can replace traditional chromate-containing coating systems.
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
C04B 28/34 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
A modified electroplated nickel-based metallic alloy coating and method of forming the same is provided. The electroplated coatings exhibit unique microstructure and composition which improves performance over conventional metallic materials. The coatings have significantly higher strength at elevated service temperatures.
A modified electroplated nickel-based metallic alloy coating and method of forming the same is provided. The electroplated coatings exhibit unique microstructure and composition which improves performance over conventional metallic materials. The coatings have significantly higher strength at elevated service temperatures.
A protective coating system is described that is characterized by fluid impermeability and a reduced coefficient of friction. The coating system includes a carbide-based thermal spray composition; a low friction layer; and a sealant impregnated into the low friction layer. Unlike conventional materials, the coating systems of the present invention achieve and maintain sealing surfaces, without adversely impacting lubricity, wear resistance and corrosion resistance during the service life of the coated component.
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
F01D 5/18 - Hollow bladesHeating, heat-insulating, or cooling means on blades
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
A unique sequence of steps is provided to reduce contaminants along one or more surfaces and faces of gold evaporative sources without deleteriously impacting the structure of the gold evaporative sources. Edges are deburred; contaminants are successfully removed therealong; and surface smoothness is substantially retained. The resultant gold evaporative source is suitable for use in evaporative processes as a precursor to gold film deposition without the occurrence or a substantial reduction in the likelihood of spitting by virtue of significantly reduced levels of contaminants, in comparison to gold evaporative sources subject to a standard cleaning protocol.
B08B 3/08 - Cleaning involving contact with liquid the liquid having chemical or dissolving effect
B08B 3/12 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
B08B 3/10 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
B24B 39/00 - Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zoneAccessories therefor
B24B 31/06 - Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work or the abrasive material is looseAccessories therefor involving oscillating or vibrating containers
A modified and improved lithium cobalt oxide sputtering target with reduced resistivity is described. Unique modifications to the composition of the lithium cobalt oxide target allow adjustment or fine-tuning of the resistance of the target not previously possible. Incorporation of a controlled amount of one or more conductive materials into the lithium cobalt oxide composition is described alone or in combination with altering the stoichiometric ratio of Li: Co to significantly reduce resistivity and thereby enhance conductivity of the target. The result is a modified sputtering target capable of sputtering lithium-containing thin films that does not exhibit deterioration of their properties by virtue of elevated levels of conductive containing material incorporated into the target.
Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require masking. A second coating can be selectively applied onto other regions of the substrate.
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
C23C 10/56 - Diffusion of at least chromium and at least aluminium
48.
MODIFIED SLURRY COMPOSITIONS FOR FORMING IMPROVED CHROMIUM DIFFUSION COATINGS
Unique and improved chromium coatings derived from modified chromium-containing slurry formulations are disclosed. The slurry formulation includes a combination of a selected halide activator and buffer material that synergistically interact with each other to form chromium diffusion coatings with improved microstructure in comparison to chromium diffusion coatings produced from conventional chromizing processes. The coatings may be locally applied in a controlled manner with accuracy onto various parts, including those having internal sections with complex geometries, without masking any portion thereof.
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
49.
Modified slurry compositions for forming improved chromium diffusion coatings
Unique and improved chromium coatings derived from modified chromium-containing slurry formulations are disclosed. The slurry formulation includes a combination of a selected halide activator and buffer material that synergistically interact with each other to form chromium diffusion coatings with improved microstructure in comparison to chromium diffusion coatings produced from conventional chromizing processes. The coatings may be locally applied in a controlled manner with accuracy onto various parts, including those having internal sections with complex geometries, without masking any portion thereof.
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
C23C 10/20 - Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions only one element being diffused
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
C23C 10/04 - Diffusion into selected surface areas, e.g. using masks
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
50.
Methods of applying chromium diffusion coatings onto selective regions of a component
Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require masking. A second coating can be selectively applied onto other regions of the substrate.
C23C 10/14 - Solid state diffusion of only metal elements or silicon into metallic material surfaces using gases more than one element being diffused in one step
C23C 10/04 - Diffusion into selected surface areas, e.g. using masks
C23C 10/20 - Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions only one element being diffused
A novel chromate-free multi-layer coating system composed of a lithium-doped potassium silicate binder based basecoat composition that is sealed with an aluminum phosphate-based top coat composition is described. The multi-layer coating system exhibits superior corrosion and heat oxidation resistance which can replace traditional chromate-containing coating systems.
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
C04B 28/34 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C04B 111/00 - Function, property or use of the mortars, concrete or artificial stone
C04B 111/10 - Compositions characterised by the absence of a specified material
A composition based on a certain chromium-free silicate-based binder is described. The one-part slurry composition is an aqueous solution of lithium-doped potassium silicate in combination with an aluminum or aluminum alloy powder. The one-part slurry composition produces a corresponding coating exhibiting improved performance at a reduced coating thickness.
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
B05D 1/00 - Processes for applying liquids or other fluent materials
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
B05D 3/00 - Pretreatment of surfaces to which liquids or other fluent materials are to be appliedAfter-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
C23F 4/04 - Processes for removing metallic material from surfaces, not provided for in group or by physical dissolution
53.
Diffusion bonded high purity copper sputtering target assemblies
The present invention relates to novel and improved high purity diffusion bonded copper (Cu) sputtering targets having a Cu purity level of 99.9999% (6N) or greater. The target assemblies of the present invention exhibit sufficient bond strength and microstructural homogeneity, both of which are properties previously considered mutually exclusive for conventional 6N Cu target assemblies. The grain structure is characterized by an absence of alloying elements and the bonded interface is generally flat without any type of interlayer or interlocking arrangement.
The present invention relates to a high purity diffusion bonded copper (Cu) sputtering targets having a Cu purity level of 99.9999% (6N) or greater. The target assemblies of the present invention exhibit sufficient bond strength and microstructural homogeneity, both of which are properties previously considered mutually exclusive for conventional 6N Cu target assemblies. The grain structure is characterized by an absence of alloying elements and the bonded interface is generally flat without any type of interlayer or interlocking arrangement.
A novel WTi target is described as having a Ti particle size similar to that of the W particle size. The target also contains controlled microstructural multi- phases characterized by an absence of a β (titanium-tungsten) alloy lamellar phase structure. The combination of controlled microstructural phases and controlled particle size improves overall sputtering performance whereby the sputtered face reduces formation of nodules which can flake off and deposit onto the resultant film to produce film defects during sputtering.
A novel coating system is provided that allows for a single coating structure to exhibit properties previously considered mutually exclusive. A unique approach for tailoring specific properties of a coating structure as a function of location within the coating is provided with a specially designed undercoat having a columnar macrostructure and a second coating layer that is selected to be compatible with and complement the undercoat. The resultant composite coating system can maintain thermocomechanical compliance while improving various bulk and/or free surface properties of the composite coating system.
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
57.
Method and apparatus for producing diffusion aluminide coatings
A method for applying an aluminide coating includes applying an aluminum-based slurry onto an elongated member. The elongate member is introduced through an opening of a component and positioned within a cavity of the component at a location that is spaced apart from the internal surfaces of the component. Heat is applied to generate vaporized aluminum which diffuses into the internal surfaces of the component. Aluminum reacts with the internal surfaces to form an aluminide coating.
Unique and improved methods and coating apparatuses for applying diffusion aluminide materials onto internal sections of various parts are disclosed. The source material is coated onto an elongated member, such as a wire or rod, which is subsequently inserted at a specific location into a hollow cavity of the component to be coated. Improvements in the coating process and resultant coating include the ability to coat complex geometries and coat components with uniform thicknesses that do not require post-coating steps for removal of oxides and/or residual bisque.
Method of applying materials onto various parts to create a predefined pattern with improved thickness and control. A controlled amount of material is applied at a selected compound surface to produce a predetermined pattern incrementally built-up at a specific region of a surface. The improved repeatability of the process facilitates higher material utilization, reduced material waste and minimal personnel exposure to the handling of potentially hazardous materials. The material to be applied may be a dry film lubricant (DFL).
B05D 5/08 - Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface
B05C 1/02 - Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to separate articles
B41F 17/00 - Printing apparatus or machines of special types or for particular purposes, not otherwise provided for
A composition based on a certain chromium-free silicate-based binder is described. The one-part slurry composition is an aqueous solution of lithium-doped potassium silicate in combination with an aluminum or aluminum alloy powder. The one-part slurry composition produces a corresponding coating exhibiting improved performance at a reduced coating thickness.
C23C 22/48 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH < 6 not containing phosphates, hexavalent chromium compounds, fluorides or complex fluorides, molybdates, tungstates, vanadates or oxalates
C23C 22/05 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
61.
Coatings and powders, methods of making same, and uses thereof
This invention relates to thermal spray coatings, powders useful in deposition of the thermal spray coatings, methods of producing the powders, and uses of the thermal spray coatings, for example, coating of piston rings and cylinder liners of internal combustion engines. The coatings of this invention are applied by thermal spray deposition of a powder. The powder contains bimetallic carbides of chromium and molybdenum dispersed in a matrix metal. The matrix metal contains nickel/chromium/molybdenum.
C22C 29/06 - Alloys based on carbides, oxides, borides, nitrides or silicides, e.g. cermets, or other metal compounds, e. g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
C22C 30/00 - Alloys containing less than 50% by weight of each constituent
C22C 32/00 - Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of verticalzA macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
C04B 35/48 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
C23C 4/02 - Pretreatment of the material to be coated, e.g. for coating on selected surface areas
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
B32B 3/00 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form
63.
Selective oxidation of a modified MCrAlY composition loaded with high levels of ceramic acting as a barrier to specific oxide formations
A composition based on a novel MCrAlY formulation is provided for the production of protective coatings. The specific combination of the constituents of the MCrAlY formulation advantageously allows significantly high loadings of ceramic (metal oxide) while still retaining the ability to selectively oxidize aluminum to form alumina scale, a property previously not attainable with conventional MCrAlY materials when loaded with ceramics at levels of 15-45 weight percent. The alumina scale in combination with the modified MCrAlY formulation act as a barrier to specific detrimental oxide formations. The compositions of the present invention can act as protective coatings for a wide array of applications.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
This invention relates to thermally sprayed coatings of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.
B32B 3/10 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
C04B 35/48 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
C23C 4/02 - Pretreatment of the material to be coated, e.g. for coating on selected surface areas
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
B32B 3/00 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form
65.
AQUEOUS SLURRY FOR THE PRODUCTION OF THERMAL AND ENVIRONMENTAL BARRIER COATINGS AND PROCESSES FOR MAKING AND APPLYING THE SAME
An improved slurry formulation for the production of a thermal and environmental barrier coatings are provided which can withstand high temperature applications. The slurry includes a combination of a coarse ceramic powder fraction having close porosity particles and a fine ceramic powder fraction. The combination of the two powders produces a bimodal particle size distribution having a controlled amount of closed porosity that imparts desirable properties to the coating produced. The finer solid particles are interdispersed within an aqueous binder to produce a ceramic matrix with sufficient mechanical strength. The closed porosity containing coarse particles are embedded within the resultant ceramic matrix and do not disintegrate under high temperature conditions to impart a temperature resistant, non-collapsing closed porosity to the coating which can also act as an environmental barrier..
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 24/10 - Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
66.
Aqueous slurry for the production of thermal and environmental barrier coatings and processes for making and applying the same
An improved slurry formulation for the production of a thermal and environmental barrier coatings are provided which can withstand high temperature applications. The slurry includes a combination of a coarse ceramic powder fraction having close porosity particles and a fine ceramic powder fraction. The combination of the two powders produces a bimodal particle size distribution having a controlled amount of closed porosity that imparts desirable properties to the coating produced. The finer solid particles are interdispersed within an aqueous binder to produce a ceramic matrix with sufficient mechanical strength. The closed porosity containing coarse particles are embedded within the resultant ceramic matrix and do not disintegrate under high temperature conditions to impart a temperature resistant, non-collapsing closed porosity to the coating which can also act as an environmental barrier.
C09D 5/00 - Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects producedFilling pastes
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 24/10 - Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
A system and method for producing thermal spray coatings on a substrate from a liquid suspension is disclosed. The disclosed system and method include a thermal spray torch for generating a plasma and a liquid suspension delivery subsystem for delivering a flow of liquid suspension with sub-micron particles to the plasma to produce a plasma effluent. The liquid suspension delivery subsystem comprises an injector or nozzle which can produce an inert or reactive gas sheath partially or fully surrounding the plasma effluent. A sheath can also be used to isolate injection of the liquid suspension. A gas assist stream can also be employed at or near the suspension injection point. The shroud, sheath or gas assist technique can retain the sub-micron particles entrained within the plasma effluent and substantially prevent entrainment of ambient gases into the plasma effluent. The liquid suspension delivery subsystem can be arranged as an axial injection system, a radial internal injection system or an external radial injection system.
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
68.
REACTIVE GAS SHROUD OR FLAME SHEATH FOR SUSPENSION PLASMA SPRAY PROCESSES
A system and method for producing thermal spray coatings on a substrate from a liquid suspension is disclosed. The disclosed system and method include a thermal spray torch for generating a plasma and a liquid suspension delivery subsystem for delivering a flow of liquid suspension with sub-micron particles to the plasma to produce a plasma effluent. The liquid suspension delivery subsystem comprises an injector or nozzle which can produce a reactive gas shroud surrounding the plasma effluent. A flame envelope can also be used to isolate injection of the liquid suspension. The shroud or flame envelope can retain the sub-micron particles entrained within the plasma effluent and substantially prevent entrainment of ambient gases into the plasma effluent. The liquid suspension delivery subsystem can be arranged as an axial injection system, a radial internal injection system or an external radial injection system.
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
69.
TOOLING FIXTURE ASSEMBLY FOR USE IN A COATING OPERATION
A modular, rotisserie type tooling fixture assembly for use in a coating operation and method of its use are disclosed. The tooling fixture assembly includes an arbor or shaft and a retaining base with a plurality of anchor members disposed in a prescribed radial orientation from the center of the retaining base, the anchor members are uniquely configured or adapted to retain a plurality of workpieces to be coated. The tooling fixture assembly further comprises a unique workpiece masking arrangement that employs a unitary masking cap having a plurality of solid walls or surfaces adapted to cover portions of the plurality of workpieces in a masking relationship.
A modular, rotisserie type multifunctional tooling fixture assembly is disclosed. The disclosed tooling fixture assembly comprises a positioning ring having a plurality of anchor members configured or adapted to retain a plurality of workpieces to be processed, and a retaining base defining a plurality of retaining members configured to be in locking engagement with the anchor members of the positioning ring and retain a plurality of workpieces in a fixed orientation. The tooling fixture assembly has utility in various coating related processes, including coating and grit blasting operations.
A modular, rotisserie type tooling fixture assembly for use in a coating operation and method of its use are disclosed. The tooling fixture assembly includes an arbor or shaft and a retaining base with a plurality of anchor members disposed in a prescribed radial orientation from the center of the retaining base, the anchor members are uniquely configured or adapted to retain a plurality of workpieces to be coated. The tooling fixture assembly further comprises a unique workpiece masking arrangement that employs a unitary masking cap having a plurality of solid walls or surfaces adapted to cover portions of the plurality of workpieces in a masking relationship.
A high surface finish, thermally stable, multilayer slurry-based overlay system suitable for use in a severe thermal environment is disclosed. The disclosed embodiments include a basecoat layer formed from a slurry comprising ceramic pigment filled phosphate-based binder, a second layer formed from a slurry comprising metal oxide pigment or ceramic oxide pigment filled phosphate-based binder, and an optional seal coat layer formed from a phosphate-based binder substantially free of pigments.
B32B 15/02 - Layered products essentially comprising metal in a form other than a sheet, e.g. wire, particles
B05D 7/14 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
B05D 1/38 - Successively applying liquids or other fluent materials, e.g. without intermediate treatment with intermediate treatment
B32B 3/30 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids characterised by a layer formed with recesses or projections, e.g. grooved, ribbed
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
73.
MULTILAYER OVERLAY SYSTEM FOR THERMAL AND CORROSION PROTECTION OF SUPERALLOY SUBSTRATES
A high surface finish, thermally stable, multilayer slurry-based overlay system suitable for use in a severe thermal environment is disclosed. The disclosed embodiments include a basecoat layer formed from a slurry comprising ceramic pigment filled phosphate-based binder, a second layer formed from a slurry comprising metal oxide pigment or ceramic oxide pigment filled phosphate-based binder, and an optional seal coat layer formed from a phosphate-based binder substantially free of pigments
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 22/74 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process for obtaining burned-in conversion coatings
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
74.
METHOD OF FORMING A CYLINDRICAL SPUTTER TARGET ASSEMBLY
In a method of forming a cylindrical sputter target assembly, comprising the steps of: (a) providing a cylindrical backing tube; (b) providing a cylindrical sputter target, the inner diameter of which is larger than the outer diameter of the backing tube; (c) arranging the sputter target about the backing tube; and (d) bonding the sputter target to the backing tube by providing a solder layer between the backing tube and the sputter target; In accordance with the invention step (d) comprises directionally solidifying the solder layer.
This invention relates to a robot programming method that is carried out at a first location (i.e., teaching station) and a second location (i.e., application station). The second location is different from the first location. At the first location, teach data is prepared to teach motions to a robot to drive an end effector through a series of desired path points along a desired path of motion with respect to the application station. The teach data comprises at least one of robot position data elements and at least one of robot motion pattern data elements. At the second location, teach data is communicated to the robot and the robot is programmed in accordance with the teach data to drive the end effector through the series of desired path points along the desired path of motion with respect to the application station. This invention also relates to a robot programming system. The robot programming method and system are useful, for example, in thermal spray coating applications.
G05B 19/423 - Teaching successive positions by walk-through, i.e. the tool head or end effector being grasped and guided directly, with or without servo-assistance, to follow a path
This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.
C04B 35/48 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
C04B 35/49 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates containing also titanium oxide or titanates
B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
B32B 19/00 - Layered products essentially comprising natural mineral fibres or particles, e.g. asbestos, mica
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
This invention relates to dense, vertically cracked thermal barrier coatings made from high purity yttria or ytterbia stabilized zirconia powders. The high purity yttria or ytterbia stabilized zirconia powder consisting essentially of less than about 0.01 weight percent silicon dioxide (silica), less than about 0.002 weight percent aluminum oxide (alumina), less than about 0.005 weight percent calcium oxide, less than about 0.005 weight percent ferric oxide, less than about 0 to about 0.002 weight percent magnesium oxide, less than about 0 to about 0.005 weight percent titanium dioxide, from about 1.5 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria), less than 0.1 weight percent other impurity oxides, and the balance zirconium oxide (zirconia) and the balance zirconium oxide (zirconia). The thermal barrier coatings are intended to be used in cyclic thermal environments such as for gas turbine blades, vanes and seal surfaces exposed in the hot section of gas turbine engines.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
B05D 3/02 - Pretreatment of surfaces to which liquids or other fluent materials are to be appliedAfter-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
78.
Thermal barrier coatings and articles made therefrom
A thermally sprayed coating, coating system and coated article are disclosed. The disclosed embodiments of the thermally sprayed coating, coating system and coated article use a customized ceramic powder comprising ceramic powder particles having an average particle size of about 25 to about 75 microns. In particular, the ceramic powder particles contain from about 70 to about 95 percent by weight of a zirconia-based component, with the balance being an (alumina+silica)-based component and wherein said ceramic powder particles comprise micronized sub-particles of the zirconia-based component and the (alumina+silica)-based component.
B32B 5/00 - Layered products characterised by the non-homogeneity or physical structure of a layer
B32B 5/16 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer formed of particles, e.g. chips, chopped fibres, powder
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
This invention relates to thermal spray coatings, powders useful in deposition of the thermal spray coatings, methods of producing the powders, and uses of the thermal spray coatings, for example, coating of piston rings and cylinder liners of internal combustion engines. The coatings of this invention are applied by thermal spray deposition of a powder. The powder contains bimetallic carbides of chromium and molybdenum dispersed in a matrix metal. The matrix metal contains nickel/chromium/molybdenum.
C22C 30/00 - Alloys containing less than 50% by weight of each constituent
C22C 29/06 - Alloys based on carbides, oxides, borides, nitrides or silicides, e.g. cermets, or other metal compounds, e. g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
F16J 9/26 - Piston-rings, seats thereforRing sealings of similar construction in general characterised by the use of particular materials
This invention relates to erosion resistant coatings comprising at least 2 sublayer systems in which each sublayer system is separated from another by an interlayer, wherein (i) each sublayer system is the same or different and comprises at least 4 layers, (ii) said layers comprise alternating layers of a nitride-containing compound of stoichiometric composition and a nitride-containing compound of nonstoichiometric composition, (iii) each sublayer system has a thickness of greater than about 0.4 microns, and (iv) each interlayer is the same or different and comprises a metal-containing compound. This invention also relates to a method for producing the coatings and to articles, e.g., gas turbine compressor rotor blade and stator vanes, coated with the coatings.
C23C 16/00 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
This invention relates in part to thermal barrier coating systems that comprise at least one metallic or metallic/ceramic inner layer deposited onto a substrate, at least one ceramic intermediate layer deposited onto the inner layer, and at least one ceramic outer layer deposited onto the intermediate layer. The ceramic intermediate layer is a thermally sprayed coating having a plurality of macrocracks distributed throughout the intermediate layer. The ceramic outer layer is a thermally sprayed coating made from composite ceramic powder particles that include a zirconia-based component and an (alumina + silica)-based component. The ceramic outer layer is substantially free of macrocracks. This invention also relates in part to methods of forming thermal barrier coating systems, and articles coated with thermal barrier coating systems. The thermal barrier coating systems are suitable for protecting components exposed to high temperature environments, such as the thermal environment of a gas turbine engine.
C23C 4/08 - Metallic material containing only metal elements
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
F01D 25/00 - Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
82.
POLYURETHANE COMPOSITION FOR CMP PADS AND METHOD OF MANUFACTURING SAME
Polyurethane composition based on a certain polyether and polyester prepolymer reaction mixture, wherein the composition is utilized in manufacturing chemical mechanical polishing/planarizing (CMP) pads. The CMP pads have low rebound and can dissipate irregular energy as well as stabilize polishing to yield improved uniformity and less dishing of the substrate.
The invention relates to gas turbine engine seal systems having a rotating member with an abrasive tip surface disposed in rub relationship to a stationary seal member with an abradable surface. The abrasive tip surface is coated with a metallic alloy matrix having ceramic abrasive particles embedded in and projecting from the matrix. The abradable seal surface is coated with a ceramic coating. The rub relationship affords a tight operating clearance between the rotating member and the stationary seal member, thereby improving engine efficiency, reducing fuel consumption and minimizing overhaul downtime.
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
84.
COATING SYSTEM FOR CLEARANCE CONTROL IN ROTATING MACHINERY
The invention relates to gas turbine engine seal systems having a rotating member with an abrasive tip surface disposed in rub relationship to a stationary seal member with an abradable surface. The abrasive tip surface is coated with a metallic alloy matrix having ceramic abrasive particles embedded in and projecting from the matrix. The abradable seal surface is coated with a ceramic coating. The rub relationship affords a tight operating clearance between the rotating member and the stationary seal member, thereby improving engine efficiency, reducing fuel consumption and minimizing overhaul downtime.
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
An aqueous phosphoric bonding solution consists essentially of phosphoric acid, a source of magnesium ions, and a leachable corrosion inhibitor. The bonding solution is stable with respect to inorganic metal particles, such as aluminum, which are admixed to the bonding solution for the preparation of a coating slurry. Metal parts coated with the coating compositions have very satisfactory properties such as heat and corrosion resistance.
C23F 11/00 - Inhibiting corrosion of metallic material by applying inhibitors to the surface in danger of corrosion or adding them to the corrosive agent
C23F 11/18 - Inhibiting corrosion of metallic material by applying inhibitors to the surface in danger of corrosion or adding them to the corrosive agent in other liquids using inorganic inhibitors
C23F 15/00 - Other methods of preventing corrosion or incrustation
The invention relates to a tube target (50) for sputtering, having a target (46) disposed on a cylindrical carrier tube. Said target (46) is divided into a plurality of segments. The target (46) comprises at least one groove (51 – 54) diagonal to the axis of rotation thereof.
This invention relates to ceramic powders comprising a zirconia-based component, e.g., yttria-stabilized zirconia, and an (alumina+silica)-based component, e.g., mullite. The ceramic powders are useful for forming thermal shock resistant coatings having the same composition, through deposition by thermal spray devices. This invention also relates to thermal barrier coating systems suitable for protecting components exposed to high temperature environments, such as the thermal environment of a gas turbine engine. This invention further relates to forming free-standing solid ceramic articles.
C04B 35/10 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on aluminium oxide
C04B 35/482 - Refractories from grain sized mixtures
C04B 35/48 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
An aqueous phosphoric bonding solution consists essentially of phosphoric acid, a source of magnesium ions, and a leachable corrosion inhibitor. The bonding solution is stable with respect to inorganic metal particles, such as aluminum, which are admixed to the bonding solution for the preparation of a coating slurry. Metal parts coated with the coating compositions have very satisfactory properties such as heat and corrosion resistance.
C23F 11/00 - Inhibiting corrosion of metallic material by applying inhibitors to the surface in danger of corrosion or adding them to the corrosive agent
C23F 11/18 - Inhibiting corrosion of metallic material by applying inhibitors to the surface in danger of corrosion or adding them to the corrosive agent in other liquids using inorganic inhibitors
C23F 15/00 - Other methods of preventing corrosion or incrustation
B05D 1/00 - Processes for applying liquids or other fluent materials
B05D 5/00 - Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
B05D 7/14 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
An aqueous phosphoric bonding solution consists essentially of phosphoric acid, a source of magnesium ions, and a leachable corrosion inhibitor. The bonding solution is stable with respect to inorganic metal particles, such as aluminum, which are admixed to the bonding solution for the preparation of a coating slurry. Metal parts coated with the coating compositions have very satisfactory properties such as heat and corrosion resistance.
C23C 22/74 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process for obtaining burned-in conversion coatings
C04B 28/34 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
90.
Method of reducing porosity in thermal spray coated and sintered articles
This invention relates to an article having a reduced porosity and a method for sealing porosity of at least a portion of an outer porous surface of an article, said method comprising (i) applying a sealant solution on the outer porous surface of said article, (ii) infiltrating at least a portion of the outer porous surface with said sealant solution, and (iii) allowing the infiltrated sealant solution to react, thereby forming an infiltrated solid precipitate, said infiltrated solid precipitate sealing the porosity of at least a portion of the outer porous surface of said article. The method is useful, for example, in the protection of integrated circuit manufacturing equipment, internal chamber components, and electrostatic chuck manufacture.
B32B 3/26 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids
91.
High purity zirconia-based thermally sprayed coatings
This invention relates to thermally sprayed coatings of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.
C23C 4/10 - Oxides, borides, carbides, nitrides or silicidesMixtures thereof
B32B 3/00 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form
C04B 35/48 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
C04B 35/505 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on rare earth compounds based on yttrium oxide
This invention relates to articles coated with a thermally sprayed coating of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). The articles include, for example, blades, vanes and seal surfaces of gas turbine engines coated with a thermal barrier coating.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
−6 standard cubic centimeters per second. The thermal sprayed bondcoat layer comprises an alloy of MCrAlM′ wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M′ is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof. The alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns. The coatings are useful for extending the service life under severe conditions, such as those associated with metallurgical vessels' lances, nozzles and tuyeres.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
This invention relates to coatings for a metal or non-metal substrate comprising (i) a thermal sprayed bondcoat layer applied to said substrate comprising an alloy of MCrAlM' wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M' is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and wherein M comprises from about 35 to about 80 weight percent of said alloy, Cr comprises from about 15 to about 45 weight percent of said alloy, Al comprises from about 5 to about 30 weight percent of said alloy, and M' comprises from about 0.01 to about 1.0 weight percent of said alloy, said alloy thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns, said bondcoat having a surface roughness of at least 200 micro-inches, and said bondcoat having a thermal expansion of about 6.5 millimeters per meter or less between a temperature of from about 25°C to about 525°C, and (ii) a thermal sprayed ceramic layer applied to said bondcoat layer; wherein said coating has a helium leak rate of less than 6 x 10'6 standard cubic centimeters per second. The coatings are useful for extending the service life under severe conditions, such as those associated with metallurgical vessels' lances, nozzles and tuyeres.
C23C 4/08 - Metallic material containing only metal elements
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
−6 standard cubic centimeters per second. The thermal sprayed bondcoat layer comprises (i) a thermal sprayed inner layer alloy, and (ii) a thermal sprayed outer layer alloy. The inner layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 50 microns. The outer layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 30 microns to about 100 microns. The coatings are useful for extending the service life under severe conditions, such as those associated with metallurgical vessels' lances, nozzles and tuyeres.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
This invention relates to thermally sprayed coatings having an amorphous-nanocrystalline- microcrystalline composition structure, said thermally sprayed coating comprising from about 1 to about 95 volume percent of an amorphous phase, from about 1 to about 80 volume percent of a nanocrystalline phase, and from about 1 to about 90 volume percent of a microcrystalline phase, and wherein said amorphous phase, nanocrystalline phase and microcrystalline phase comprise about 100 volume percent of said thermally sprayed coating. This invention also relates to methods for producing the coatings, thermal spray processes for producing the coatings, and articles coated with the coatings. The thermally sprayed coatings of this invention provide enhanced wear and corrosion resistance for articles used in severe environments (e.g., landing gears, airframes, ball valves, gate valves (gates and seats), pot rolls, and work rolls for paper processing).
C23C 4/04 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
C23C 24/04 - Impact or kinetic deposition of particles
This invention relates to erosion resistant coatings comprising at least 2 sublayer systems in which each sublayer system is separated from another by an interlayer, wherein (i) each sublayer system is the same or different and comprises at least 4 layers, (ii) said layers comprise alternating layers of a nitride-containing compound of stoichiometric composition and a nitride-containing compound of nonstoichiometric composition, (iii) each sublayer system has a thickness of greater than about 0.4 microns, and (iv) each interlayer is the same or different and comprises a metal-containing compound. This invention also relates to a method for producing the coatings and to articles, e.g., gas turbine compressor rotor blade and stator vanes, coated with the coatings.
This invention relates to erosion resistant coatings comprising at least 2 sublayer systems in which each sublayer system is separated from another by an interlayer, wherein (i) each sublayer system is the same or different and comprises at least 4 layers, (ii) said layers comprise alternating layers of a nitride- containing compound of stoichiometric composition and a nitride-containing compound of nonstoichiometric composition, (iii) each sublayer system has a thickness of greater than about 0.4 microns, and (iv) each interlayer is the same or different and comprises a metal -containing compound. This invention also relates to a method for producing the coatings and to articles, e.g., gas turbine compressor rotor blade and stator vanes, coated with the coatings.
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 28/04 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of inorganic non-metallic material
C23C 14/06 - Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
99.
Low thermal expansion bondcoats for thermal barrier coatings
This invention relates to low thermal expansion bondcoats for thermal barrier coatings. The bondcoats comprise: (i) an inner layer comprising an inner layer alloy of MCrAlM′, and (ii) an outer layer comprising an outer layer alloy of MCrAlM′, wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M′ is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof. The inner layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 50 microns. The outer layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 30 microns to about 100 microns. The bondcoat has a thermal expansion of about 6.5 millimeters per meter or less between a temperature of from about 25° C. to about 525° C.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/18 - Layered products essentially comprising metal comprising iron or steel
This invention relates to thermally spray coated work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture comprising a cylindrical- like structure having an outer peripheral surface and a thermally sprayed coating on the outer peripheral surface of said cylindrical-like structure, said thermally sprayed coating comprising from about 65 to about 95 weight percent of one or more Group Vl metal carbides, and from about 5 to about 35 weight percent of one or more transition metals selected from chromium, manganese, iron, cobalt and nickel. This invention also relates to a process for preparing the work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture, a method for manufacturing metal or metal alloy, e.g., aluminum alloy, sheet using the thermally spray coated work rolls, and a thermal spray powder for coating the outer peripheral surface of the work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture.
patents
