Patents by Inventor Taylor K. Blair
Taylor K. Blair has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11976013Abstract: An article may include a substrate including a ceramic matrix composite (CMC); a composite coating layer including a first coating material that includes a rare-earth disilicate and a second coating material that includes at least one of a rare-earth monosilicate, a CMAS-resistant material, or a high-temperature dislocating material, where the second coating material forms a substantially continuous phase in the composite coating layer.Type: GrantFiled: September 21, 2018Date of Patent: May 7, 2024Assignees: Rolls-Royce Corporation, Rolls-Royce plcInventors: Stephanie Gong, Ngunjoh Lawrence Ndamka, Matthew R. Gold, Li Li, Taylor K. Blair, Sunny Chang, Ann Bolcavage
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Patent number: 11958787Abstract: The disclosure describes braze tape coatings and technique to form articles with differing physical properties in different layers or regions of the article. An example method includes forming a braze tape defining at least one layer that includes a first segment and a second segment. A portion of the second segment in the plane is adjacent to a portion of the first segment in a plane of the layer. The method also includes positioning the braze tape on a surface of a substrate, the plane of the layer of the braze tape being parallel to the surface of the substrate. The method also includes heating the braze tape to melt a constituent of at least one of the first coating material and the second coating material to form a densified coating on the surface of the substrate.Type: GrantFiled: December 11, 2020Date of Patent: April 16, 2024Assignees: Rolls-Royce Corporation, Rolls-Royce High Temperature Composites, Inc.Inventors: Robert Alexander Sean Golden, Sungbo Shim, Li Li, Taylor K. Blair
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Patent number: 11952317Abstract: An example article includes a substrate and a barrier coating on the substrate. The barrier coating includes a matrix including a rare-earth disilicate extending from an inner interface facing the substrate to an outer surface opposite the inner interface. The barrier coating includes a graded volumetric distribution of rare-earth oxide rich (REO-rich) phase regions in the matrix along a direction from the inner interface to the outer surface. The graded volumetric distribution defines a first volumetric density of the REO-rich phase regions at a first region of the matrix adjacent the outer surface. The graded volumetric distribution defines a second volumetric density of the REO-rich phase regions at a second region of the matrix adjacent the inner surface. The second volumetric density is different from the first volumetric density. An example technique includes forming the barrier coating on the substrate of a component.Type: GrantFiled: October 18, 2019Date of Patent: April 9, 2024Assignees: Rolls-Royce Corporation, Rolls-Royce plcInventors: Ngunjoh Lawrence Ndamka, Li Li, Stephanie Gong, Ann Bolcavage, Taylor K. Blair, Robert Golden
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Patent number: 11860080Abstract: In some examples, a system including a fluid stream monitoring system. The monitoring system includes an illumination device configured to illuminate at least some of particles suspended in a fluid stream; and an imaging device configured to image the illuminated particles at a first image plane that intersects a longitudinal axis of the fluid stream, wherein the illumination device and the imaging device are registered to the fluid stream delivery device in the first image plane, where the first image plane is substantially orthogonal to the longitudinal axis. The system includes processing circuitry configured to determine one or more physical characteristics of the fluid particles.Type: GrantFiled: December 29, 2021Date of Patent: January 2, 2024Assignees: Rolls-Royce Corporation, Rolls-Royce plcInventors: Scott Nelson, Taylor K. Blair, John Grubbs, Martyn Anthony Jones, Chris Heason
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Publication number: 20230249316Abstract: Techniques for abrasively blasting (e.g., grit blasting) components, such as ceramic or CMC components. In some examples, based on a comparison of component geometry to a target geometry, a blasting path over the surface of the component may be generated for a selected traverse speed. A computing device may control a blasting device to blast the component according to the generated blasting path with the selected traverse speed. In some examples, based on a comparison of a component geometry to a target geometry, a respective traverse speed for a blasting device relative the component for each section of a plurality of sections over a surface of the component may be generated. A computing device controls the blasting device to blast the component according to the respective traverse speeds relative over a surface of the component to remove material from the surface of the component.Type: ApplicationFiled: February 4, 2022Publication date: August 10, 2023Inventors: Taylor K. Blair, Matthew R. Gold, Austin Scherbarth, Gary Pickrell
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Publication number: 20230212086Abstract: In some examples, article used as a component for a turbine engine that operates in a high temperature environment. The article may include: a ceramic or ceramic matrix composite (CMC) substrate; and a coating on the ceramic or the CMC substrate, wherein the coating defines an outer surface of the article. The coating includes a plurality of surface features defining channels on the outer surface of the article. The channels are configured to modify a flow of molten Calcia-Magnesia-Alumina Silicate (CMAS) over the outer surface of the coating in a gas flow over the outer surface of the article to reduce accumulation of the molten CMAS on the outer surface of the article.Type: ApplicationFiled: December 30, 2021Publication date: July 6, 2023Inventors: Taylor K. Blair, Ted J. Freeman, Aaron Sippel
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Publication number: 20230204490Abstract: In some examples, a system including a fluid stream monitoring system. The monitoring system includes an illumination device configured to illuminate at least some of particles suspended in a fluid stream; and an imaging device configured to image the illuminated particles at a first image plane that intersects a longitudinal axis of the fluid stream, wherein the illumination device and the imaging device are registered to the fluid stream delivery device in the first image plane, where the first image plane is substantially orthogonal to the longitudinal axis. The system includes processing circuitry configured to determine one or more physical characteristics of the fluid particles.Type: ApplicationFiled: December 29, 2021Publication date: June 29, 2023Inventors: Scott Nelson, Taylor K. Blair, John Grubbs, Martyn Anthony Jones, Chris Heason
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Publication number: 20230192554Abstract: An article includes a substrate, an intermediate coating on the substrate, and an environmental barrier coating (EBC) on the intermediate coating. The substrate includes a ceramic, ceramic matrix composite (CMC), or superalloy. The EBC includes a rare earth disilicate. When the intermediate coating is at an initial state, such as prior to exposure to an oxidating environment, the intermediate coating includes a bond coat on the substrate and a reactive layer on the bond coat. The bond coat includes silicon, while the reactive layer includes a rare earth monosilicate or rare earth oxide. In response to oxidation of a portion of the silicon of the bond coat to form silicon dioxide, a portion of the rare earth monosilicate or rare earth oxide of the reactive layer is configured to react with at least a portion of the silicon dioxide to form a converted layer that includes a rare earth disilicate.Type: ApplicationFiled: December 22, 2021Publication date: June 22, 2023Inventor: Taylor K. Blair
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Patent number: 11655192Abstract: An example article includes a substrate and a barrier coating on the substrate extending from an inner interface facing the substrate to an outer surface opposite the inner interface. The barrier coating includes a bulk matrix and a plurality of discrete plugs inset within the bulk matrix and dispersed across the outer surface of the barrier coating. An example technique includes forming the barrier coating on the substrate of a component.Type: GrantFiled: July 25, 2019Date of Patent: May 23, 2023Assignee: Rolls-Royce CorporationInventors: Li Li, Jun Shi, Scott Nelson, Taylor K. Blair
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Patent number: 11619137Abstract: A gas turbine engine includes at least one trap that absorbs or adheres to calcium-magnesium-alumino-silicate (CMAS) entrained in intake air entering the engine.Type: GrantFiled: December 30, 2021Date of Patent: April 4, 2023Assignee: Rolls-Royce CorporationInventor: Taylor K. Blair
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Patent number: 11512379Abstract: In one example, a method for forming a coating system including a bond coat and an environmental barrier coating on a ceramic or CMC substrate, e.g., with an abradable coating on the environmental barrier coating. The method may include depositing a bond coat on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited bond coat; heat treating the as-deposited bond coat following the deposition of the as-deposited bond coat on the substrate to form a heat treated bond coat; depositing an environment barrier coating (EBC) layer on the heat treated bond coat to form as deposited EBC layer; and heat treating the as-deposited EBC layer to form a heat treated EBC layer.Type: GrantFiled: June 28, 2021Date of Patent: November 29, 2022Assignee: Rolls-Royce CorporationInventors: Li Li, Taylor K. Blair, Stephanie Gong
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Publication number: 20220002857Abstract: In one example, a method for forming a coating system including a bond coat and an environmental barrier coating on a ceramic or CMC substrate, e.g., with an abradable coating on the environmental barrier coating. The method may include depositing a bond coat on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited bond coat; heat treating the as-deposited bond coat following the deposition of the as-deposited bond coat on the substrate to form a heat treated bond coat; depositing an environment barrier coating (EBC) layer on the heat treated bond coat to form as deposited EBC layer; and heat treating the as-deposited EBC layer to form a heat treated EBC layer.Type: ApplicationFiled: June 28, 2021Publication date: January 6, 2022Inventors: Li Li, Taylor K. Blair, Stephanie Gong
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Patent number: 11092983Abstract: An example system includes at least one acoustic sensor and one optical sensor to monitor a thermal spray system controlled by a plurality of control parameters and performing a process associated with a plurality of process outputs. The system includes a computing device including a machine learning module and a control module. The machine learning module is configured to determine, based on at least the plurality of control parameters, an at least one time-dependent acoustic data signal, an at least one image data signal, and the plurality of process outputs, a relationship between the plurality of control parameters and the plurality of process outputs by machine learning. The control module is configured to control the thermal spray system to adjust the plurality of process outputs toward a plurality of respective operating ranges.Type: GrantFiled: June 14, 2019Date of Patent: August 17, 2021Assignee: Rolls-Royce CorporationInventors: Michael Cybulsky, Taylor K. Blair, Benjamin Zimmerman, Marshall Louis Sweet, Andrea Marcon
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Publication number: 20210188723Abstract: The disclosure describes braze tape coatings and technique to form articles with differing physical properties in different layers or regions of the article. An example method includes forming a braze tape defining at least one layer that includes a first segment and a second segment. A portion of the second segment in the plane is adjacent to a portion of the first segment in a plane of the layer. The method also includes positioning the braze tape on a surface of a substrate, the plane of the layer of the braze tape being parallel to the surface of the substrate. The method also includes heating the braze tape to melt a constituent of at least one of the first coating material and the second coating material to form a densified coating on the surface of the substrate.Type: ApplicationFiled: December 11, 2020Publication date: June 24, 2021Inventors: Robert Alexander Sean Golden, Sungbo Shim, Li Li, Taylor K. Blair
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Publication number: 20210024424Abstract: An example article includes a substrate and a barrier coating on the substrate extending from an inner interface facing the substrate to an outer surface opposite the inner interface. The barrier coating includes a bulk matrix and a plurality of discrete plugs inset within the bulk matrix and dispersed across the outer surface of the barrier coating. An example technique includes forming the barrier coating on the substrate of a component.Type: ApplicationFiled: July 25, 2019Publication date: January 28, 2021Inventors: Li Li, Jun Shi, Scott Nelson, Taylor K. Blair
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Patent number: 10871078Abstract: An article for use in a high-temperature environment that includes a substrate including a superalloy material, a ceramic, or a ceramic matrix composite, and an abradable coating on the substrate, the abradable coating including a rare earth silicate and a dislocator phase, the dislocator phase forms one or more distinct phase regions in the abradable coating and comprises at least one of hafnium diboride (HfB2), zirconium diboride (ZrB2), tantalum nitride (TaN or Ta2N), tantalum carbide (Ta2C), titanium diboride (TiB2), zirconium carbide (ZrC), hafnium carbide (HfC), tantalum diboride (TaB2), hafnium nitride (HfN), or niobium carbide (NbC).Type: GrantFiled: September 19, 2018Date of Patent: December 22, 2020Assignees: Rolls-Royce Corporation, Rolls-Royce plcInventors: Ngunjoh Lawrence Ndamka, Li Li, Stephanie Gong, Sunny Chang, Ann Bolcavage, Taylor K. Blair
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Patent number: 10851656Abstract: An article includes a substrate, a bond coat on the substrate, and a multilayer environmental barrier coating (EBC) on the bond coat. The multilayer EBC includes a first EBC layer defining a first thickness and a second EBC layer defining a second thickness. The first EBC layer includes a first rare earth disilicate and a first concentration of a sintering aid that includes alumina. The second EBC layer includes a second rare earth disilicate and a second concentration of the sintering aid that includes alumina, less than the first concentration of the sintering aid.Type: GrantFiled: September 25, 2018Date of Patent: December 1, 2020Assignees: Rolls-Royce Corporation, Rolls-Royce PLCInventors: Stephanie Gong, Taylor K. Blair, Ngunjoh Lawrence Ndamka, Li Li, Sunny Chang, Ann Bolcavage
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Patent number: 10724999Abstract: An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process possessing a plurality of process attributes, and a computing device including an acoustic data signal processing module configured to receive the at least one time-dependent acoustic data signal, and transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum, wherein each process attribute of the plurality of process attributes is associated with at least one respective frequency band, and a correlation module configured to determine a process attribute of the plurality of process attributes by identifying at least one characteristic of the frequency-domain spectrum.Type: GrantFiled: June 3, 2016Date of Patent: July 28, 2020Assignee: Rolls-Royce CorporationInventors: Michael Cybulsky, Raymond J. Sinatra, Matthew R. Gold, Taylor K. Blair, Gary Pickrell, Romesh Batra
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Patent number: 10695783Abstract: An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process associated with a plurality of process attributes. The example system includes a computing device including an acoustic data signal module and a control module. The acoustic data signal processing module may transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum. The control module may determine a process attribute of the plurality of process attributes that deviates from a predetermined operating range by identifying at least one characteristic of the frequency-domain spectrum, selecting at least one component of the thermal spray system based on the process attribute, and controlling the thermal spray system to adjust the process attribute toward the predetermined operating range by sending a control signal to the at least one component.Type: GrantFiled: December 6, 2017Date of Patent: June 30, 2020Assignees: Rolls-Royce Corporation, Virginia Tech Intellectual Properties, Inc., Commonwealth Center for Advanced ManufacturingInventors: Taylor K. Blair, Michael Cybulsky, Gary Pickrell, Benjamin Zimmerman, Romesh Batra, Matthew R. Gold
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Publication number: 20200172446Abstract: A method may include applying a layer comprising a carbon source on a surface of a substrate including silicon; applying a layer comprising silicon on the layer comprising elemental carbon; and heat treating at least the layer comprising the carbon source to cause carbon from the layer comprising the carbon source to react with at least one of silicon from the substrate or silicon from the layer comprising silicon to form silicon carbide.Type: ApplicationFiled: November 25, 2019Publication date: June 4, 2020Inventor: Taylor K. Blair