Patents Represented by Attorney, Agent or Law Firm F. Tyler Morrison
  • Patent number: 6924040
    Abstract: A ceramic material has particular utility as a thermal insulating or thermal barrier coating on metallic substrates. The ceramic material includes gadolinia and hafnia, preferably forming gadolinia-hafnia. This material exhibits chemical stability, thermal stability and thermal insulating properties superior to those of currently used thermal barrier ceramics, and also provides resistance to sintering and erosion comparable to currently used ceramics. A preferred material has between about 3-70 mol. % hafnia, balance hafnia.
    Type: Grant
    Filed: December 21, 2001
    Date of Patent: August 2, 2005
    Assignee: United Technologies Corporation
    Inventor: Michael J. Maloney
  • Patent number: 6781296
    Abstract: A method includes providing an electron gun having a first head with a thermionic electron source and an accelerating electrode, and further includes replacing the first head with a second head having a power rating substantially different than that of the first head, and subsequently operating the electron gun without replacing the accelerating electrode. The electron gun may further include a platform spaced apart from the accelerating electrode and having an adjustably located locating member that engages a reference member on the head to position the head in three dimensions relative to the accelerating electrode. The platform may be adjustably spaced from the accelerating electrode in order vary the distance between the electron source and the accelerating electrode.
    Type: Grant
    Filed: December 11, 2000
    Date of Patent: August 24, 2004
    Assignee: United Technologies Corporation
    Inventor: Brian E. Mensinger
  • Patent number: 6471881
    Abstract: A method is disclosed for providing a TBC system including grooves or other features between the bond coat/substrate and the ceramic thermally insulating layer. The features are initially provided by selectively removing material to define the features, for example by laser. Any disturbed surface layer, e.g., re-cast material in the case of a laser or plastically worked material in the case of machining, is then chemically removed, leaving the remaining material with a microstructure of a more uniform geometry, and free of disturbed material. The ceramic layer is then applied. TBC systems using the method show improved durability, with lives up to 4× longer than prior TBC systems.
    Type: Grant
    Filed: November 23, 1999
    Date of Patent: October 29, 2002
    Assignee: United Technologies Corporation
    Inventors: Yan Chai, Gary M. Lomasney, Keith Douglas Sheffler
  • Patent number: 6435830
    Abstract: According to the invention, an article that is exposed to high temperatures, e.g., over 1000° C. during operation is disclosed. In one embodiment, a turbine blade for a gas turbine engine includes a directionally solidified metallic substrate, e.g., a superalloy, which defines an airfoil, a root and a platform located between the blade and root. The platform has an underside adjacent the root, and a corrosion resistant overlay coating such as an MCrAlY is located on the underside of the platform and the neck. The applied coating prevents corrosion and stress corrosion cracking of blade in these regions. Where the airfoil is also coated, the airfoil coating may have a composition different from that of the coating on the underplatform surfaces.
    Type: Grant
    Filed: December 20, 1999
    Date of Patent: August 20, 2002
    Assignee: United Technologies Corporation
    Inventors: William Patrick Allen, Walter E. Olson, Dilip M. Shah, Alan David Cetel
  • Patent number: 6435826
    Abstract: According to the invention, an article that is exposed to high temperatures, e.g., over 1000° C. during operation is disclosed. In one embodiment, a turbine blade for a gas turbine engine includes a directionally solidified metallic substrate, e.g., a superalloy, which defines an airfoil, a root and a platform located between the blade and root. The platform has an underside adjacent the root, and a corrosion resistant noble metal-containing aluminide coating is located on portions of the blade susceptible to corrosion and/or stress corrosion cracking, such as the underside of the platform and the neck. The applied coating prevents corrosion and stress corrosion cracking of blade in these regions.
    Type: Grant
    Filed: April 16, 2001
    Date of Patent: August 20, 2002
    Assignee: United Technologies Corporation
    Inventors: William Patrick Allen, Walter E. Olson
  • Patent number: 6435835
    Abstract: According to the invention, an article that is exposed to high temperatures, e.g., over 1000° C. during operation is disclosed. In one embodiment, a turbine blade for a gas turbine engine includes a directionally solidified metallic substrate, e.g., a superalloy, which defines an airfoil, a root and a platform located between the blade and root. The platform has an underside adjacent the root, and a corrosion resistant noble metal-containing aluminide coating is located on portions of the blade susceptible to corrosion and/or stress corrosion cracking, such as the underside of the platform and the neck. The applied coating prevents corrosion and stress corrosion cracking of blade in these regions.
    Type: Grant
    Filed: December 20, 1999
    Date of Patent: August 20, 2002
    Assignee: United Technologies Corporation
    Inventors: William Patrick Allen, Walter E. Olson
  • Patent number: 6383570
    Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.
    Type: Grant
    Filed: December 21, 2000
    Date of Patent: May 7, 2002
    Assignee: United Technologies Corporation
    Inventors: Sudhangshu Bose, Dinesh K. Gupta, Jeanine T. Marcin, Nicholas E. Ulion
  • Patent number: 6365236
    Abstract: Methods of producing layered ceramic coatings in which some layers contain porosity are described, as are the coatings produced. The different layers are applied at different temperature conditions by periodically inserting a heat blocking shield between the heat source and either the evaporation source and/or an external heater. As applied, some of the layers have a Zone I structure and some have a Zone II type structure. Heat treatment may be used to increase the porosity in the Zone I structure layers.
    Type: Grant
    Filed: December 20, 1999
    Date of Patent: April 2, 2002
    Assignee: United Technologies Corporation
    Inventor: Michael J. Maloney
  • Patent number: 6358002
    Abstract: An air seal is illustrated as used in a gas turbine engine. The seal includes at least a seal substrate, a relatively dense, erosion resistant ceramic layer applied over the bond coat, and an abradable ceramic layer applied in a local area over the dense ceramic layer. The abradable ceramic interacts with a component moving relative to the seal, such as a turbine blade that moves relative to the seal, and cooperates with the moving component to provide sealing and thermal insulation.
    Type: Grant
    Filed: August 10, 1999
    Date of Patent: March 19, 2002
    Assignee: United Technologies Corporation
    Inventors: Randall Richard Good, George Everett Foster
  • Patent number: 6352264
    Abstract: An air seal for use in a gas turbine engine is disclosed. The seal includes a seal substrate, and an abradable layer on the substrate, with the abradable including a thermoset polymer and a thermoplastic polymer. The abradable may also include a filler to add porosity, or provide lubrication, to enhance abradability.
    Type: Grant
    Filed: December 17, 1999
    Date of Patent: March 5, 2002
    Assignee: United Technologies Corporation
    Inventors: William John Dalzell, Jr., Stuart Alan Sanders, George Lee Crawford, Frederick Clell Walden, William J. Woodard
  • Patent number: 6284390
    Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.
    Type: Grant
    Filed: June 12, 1998
    Date of Patent: September 4, 2001
    Assignee: United Technologies Corporation
    Inventors: Sudhangshu Bose, Dinesh K. Gupta, Jeanine D. Marcin, Nicholas E. Ulion
  • Patent number: 6284323
    Abstract: A ceramic material has particular utility as a thermal insulating or thermal barrier coating on metallic substrates. The ceramic material includes gadolinia and zirconia, preferably forming gadolinia-zirconia oxide. The material may include fluorite and pyrochlore structure. This material exhibits chemical stability, thermal stability and thermal insulating properties superior to those of currently used thermal barrier ceramics, and also provides resistance to sintering and erosion comparable to currently used ceramics. A preferred material has between about 5-60 mol. % gadolinia.
    Type: Grant
    Filed: December 15, 1999
    Date of Patent: September 4, 2001
    Assignee: United Technologies Corporation
    Inventor: Michael J. Maloney
  • Patent number: 6270318
    Abstract: According to the invention, an article that is exposed to high temperatures, e.g., over 1000° C. during operation is disclosed. In one embodiment, a turbine blade for a gas turbine engine includes a directionally solidified metallic substrate, e.g., a superalloy, which defines an airfoil, a root and a platform located between the blade and root. The platform has an underside adjacent the root, and a corrosion resistant ceramic overlay coating such as a stabilized zirconia is located on the underside of the platform and the neck. The applied coating prevents corrosion and stress corrosion cracking of blades in these regions.
    Type: Grant
    Filed: December 20, 1999
    Date of Patent: August 7, 2001
    Assignee: United Technologies Corporation
    Inventors: Dilip M. Shah, Alan David Cetel
  • Patent number: 6270852
    Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.
    Type: Grant
    Filed: October 14, 1999
    Date of Patent: August 7, 2001
    Assignee: United Technologies Corporation
    Inventors: Nicholas E. Ulion, Jeanine T. Marcin, Dinesh K. Gupta, Sudhangshu Bose
  • Patent number: 6231991
    Abstract: A new family of ceramic materials is identified having particular utility as thermal insulating or thermal barrier coatings on metallic substrates. The ceramic materials have a pyrochlore structure and are typified by the composition A2B2O7 where A and B are various ions and 0 is oxygen. A may have a positive charge of 3+ or 2+ and B may have a positive charge of 4+ or 5+. These materials are characterized by having chemical stability, thermal stability and thermal insulating properties superior to those of currently used thermal barrier ceramics. An example pyrochlore material is lanthanum zirconate.
    Type: Grant
    Filed: November 8, 1999
    Date of Patent: May 15, 2001
    Assignee: United Technologies Corporation
    Inventor: Michael J. Maloney
  • Patent number: 6187453
    Abstract: An article having an improved thermal barrier coating is disclosed. The article includes a superalloy substrate, and an adherent alumina layer generated on the substrate surface. The article also includes a layer of ceramic material forming a columnar grain, thermal barrier coating on the alumina layer. The coating is composed of a generally homogeneous mixture of two materials, such as yttria and ceria and preferably at least about 5 w/o yttria, balance, ceria. The article may also include an intermediate ceramic bond coat, such as a layer of yttria strengthened zirconia, to enhance the adherence of the thermal barrier coating.
    Type: Grant
    Filed: July 17, 1998
    Date of Patent: February 13, 2001
    Assignee: United Technologies Corporation
    Inventor: Michael J. Maloney
  • Patent number: 6177200
    Abstract: A ceramic material has particular utility as a thermal insulating or thermal barrier coating on metallic substrates. The ceramic material includes gadolinia and zirconia, preferably forming gadolinia-zirconia oxide. The material may include fluorite and pyrochlore structure. This material exhibits chemical stability, thermal stability and thermal insulating properties superior to those of currently used thermal barrier ceramics, and also provides resistance to sintering and erosion comparable to currently used ceramics. A preferred material has between about 5-60 mol. % gadolinia.
    Type: Grant
    Filed: October 1, 1998
    Date of Patent: January 23, 2001
    Assignee: United Technologies Corporation
    Inventor: Michael J. Maloney
  • Patent number: 6089825
    Abstract: An air seal for use in a gas turbine engine includes reduced susceptibility to deflagration during operating conditions in which an excessive amount of seal material is liberated from the seal and ingested into the engine. The seal includes a seal substrate, and a thermally sprayed metallic bond layer applied to the seal substrate. The bond layer includes nickel and aluminum. The seal also includes a thermally sprayed abradable seal layer applied to the bond layer. The abradable material is composed of aluminum powder and silicon powder forming a metal matrix, and co-deposited methyl methacrylate particles embedded as filler in the metal matrix. The filler is less likely to deflagrate compared to conventionally used materials such as polyester.
    Type: Grant
    Filed: December 18, 1998
    Date of Patent: July 18, 2000
    Assignee: United Technologies Corporation
    Inventors: Frederick Clell Walden, George Lee Crawford, William John Dalzell, Jr.
  • Patent number: 6063212
    Abstract: Heat treated, spray formed articles are disclosed which exhibit crack growth rates and resistance to stress rupture comparable to corresponding, forged articles. The articles are first formed by depositing molten metal droplets, e.g., of IN 718, on a substrate to form a rough article. The articles are HIP'ed and then processed by heat treating, which includes solution, stabilization and precipitation heat treatments. The resultant articles have fine average grain sizes compared to forged and conventionally heat treated material, as well as yield and tensile strengths comparable to forged material. Importantly, the articles also exhibit low crack growth rates and stress rupture resistance, e.g., comparable to forged material, and have an isotropic microstructure. The articles can be used in place of forged articles.
    Type: Grant
    Filed: May 12, 1998
    Date of Patent: May 16, 2000
    Assignee: United Technologies Corporation
    Inventor: Antonio C. Cabral
  • Patent number: 6060177
    Abstract: An overcoat is applied over thermal barrier coatings such as YSZ or other columnar grain ceramic. The exposed surface of the TBC is prepared to ensure that it is clean and has a proper roughness. The surface is then heated and an overcoat material such as a solid solution of chromia and alumina is deposited on the exposed surface, for example by plasma spraying to form a continuous overcoat on the TBC. The overcoat is preferably corrosion and erosion resistant, and inhibits the migration of oxygen to the underlying TBC and alumina layer.
    Type: Grant
    Filed: February 19, 1998
    Date of Patent: May 9, 2000
    Assignee: United Technologies Corporation
    Inventors: Norman S. Bornstein, Raymond F. Zatorski