Patents by Inventor Bernard Patrick Bewlay

Bernard Patrick Bewlay 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).

  • Ceramic cores for casting superalloys and refractory metal composites, and related processes
    Patent number: 7946335
    Abstract: A rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE4Al2O9), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.
    Type: Grant
    Filed: August 27, 2010
    Date of Patent: May 24, 2011
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Stephen Francis Bancheri, Frederic Joseph Klug
  • CERAMIC CORES FOR CASTING SUPERALLOYS AND REFRACTORY METAL COMPOSITES, AND RELATED PROCESSES
    Publication number: 20100319870
    Abstract: A rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE4Al2O9), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.
    Type: Application
    Filed: August 27, 2010
    Publication date: December 23, 2010
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick Bewlay, Stephen Francis Bancheri, Frederic Joseph Klug
  • Ceramic lamp having molybdenum-rhenium end cap and systems and methods therewith
    Patent number: 7852006
    Abstract: A lamp comprising an arc envelope and a molybdenum-rhenium end structure coupled to the arc envelope.
    Type: Grant
    Filed: June 30, 2005
    Date of Patent: December 14, 2010
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Bruce Alan Knudsen, Mohamed Rahmane, James Anthony Brewer, James Scott Vartuli, Alan George Chalmers
  • Hafnia-modified rare-earth metal-based ceramic bodies and casting processes performed therewith
    Patent number: 7845390
    Abstract: Compositions suitable for use as cores and shell molds for casting of reactive metal alloys, and casting processes for producing components from such alloys. The composition contains a sintered particulate material of hafnia and at least one additional metal oxide in amounts to yield a ceramic composition containing up to 70 molar percent of hafnia, wherein the additional metal oxide is a rare-earth oxide, the sintered particulate material contains first and second phases, the first phase is the rare-earth oxide and hafnia in solid solution, the second phase is a compound of the rare-earth oxide and hafnia, and the second phase is less reactive with the reactive metal alloy than the first phase.
    Type: Grant
    Filed: January 31, 2008
    Date of Patent: December 7, 2010
    Assignee: General Electric Company
    Inventors: Stephen Francis Bancheri, Frederic Joseph Klug, Bernard Patrick Bewlay
  • Ceramic cores for casting superalloys and refractory metal composites, and related processes
    Patent number: 7798201
    Abstract: A rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE4Al2O9), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.
    Type: Grant
    Filed: August 24, 2007
    Date of Patent: September 21, 2010
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Stephen Francis Bancheri, Frederic Joseph Klug
  • Articles for use with highly reactive alloys
    Patent number: 7790101
    Abstract: Articles for use with highly reactive alloys that include a graphite crucible having an interior, and at least a first protective layer applied to the interior of the graphite crucible in which the graphite crucible having the first protective layer is used for melting highly reactive alloys.
    Type: Grant
    Filed: December 27, 2006
    Date of Patent: September 7, 2010
    Assignee: General Electric Company
    Inventors: Thomas Joseph Kelly, Michael James Weimer, Bernard Patrick Bewlay, Michael Francis Xavier Gigliotti, Jr.
  • Methods for making refractory crucibles
    Patent number: 7761969
    Abstract: Methods for making refractory crucibles capable of managing thermal stresses and suitable for melting highly reactive alloys, the method involving providing a crucible having at least a facecoat and a backing, heating at least one retaining ring, applying the at least one retaining ring about at least a portion of the backing of the crucible; and allowing the at least one retaining ring to cool and shrink-fit about the crucible.
    Type: Grant
    Filed: November 30, 2007
    Date of Patent: July 27, 2010
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Michael Francis Xavier Gigliotti, Mohamed Rahmane, Thomas Joseph Kelly, Michael James Weimer, Sairam Sundaram
  • Refractory metal intermetallic composites based on niobium-silicides, and related articles
    Patent number: 7704335
    Abstract: A refractory composition is described, containing niobium, silicon, titanium, and at least one of rhenium and ruthenium. The amount of silicon in the composition is at least about 9 atom %, and the amount of titanium present is less than about 26 atom %, based on total atomic percent. Turbine engine components formed from such a composition are also disclosed.
    Type: Grant
    Filed: July 26, 2005
    Date of Patent: April 27, 2010
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Laurent Cretegny, Pazhayannur Ramanathan Subramanian, Melvin Robert Jackson
  • Oxidation resistant coatings for molybdenum silicide-based composite articles
    Patent number: 7622150
    Abstract: An environmentally resistant coating comprising silicon, titanium, chromium, and a balance of niobium and molybdenum for turbine components formed from molybdenum silicide-based composites. The turbine component may further include a thermal barrier coating disposed upon an outer surface of the environmentally resistant coating comprising zirconia, stabilized zirconia, zircon, mullite, and combinations thereof. The molybdenum silicide-based composite turbine component coated with the environmentally resistant coating and thermal barrier coating is resistant to oxidation at temperatures in the range from about 2000° F. to about 2600° F. and to pesting at temperatures in the range from about 1000° F. to about 1800° F.
    Type: Grant
    Filed: September 24, 2002
    Date of Patent: November 24, 2009
    Assignee: General Electric Company
    Inventors: Ji-Cheng Zhao, Bernard Patrick Bewlay, Melvin Robert Jackson
  • NIOBIUM SILICIDE-BASED TURBINE COMPONENTS, AND RELATED METHODS FOR LASER DEPOSITION
    Publication number: 20090280269
    Abstract: A turbine component formed from a niobium silicide-based composition is described. The component can be compositionally-graded through at least a portion of its structure. A turbine blade formed from a composition which includes a niobium silicide alloy is also described. The blade includes an airfoil; an airfoil tip region; a platform on which the airfoil is mounted; and a dovetail root attached to an underside of the platform. The niobium silicide alloy in at least one portion of the turbine blade is compositionally different from the niobium silicide alloy in another portion of the blade. Processes for fabricating a niobium silicide-based turbine article are also described, using laser cladding techniques. Repair methods are also set forth in the application.
    Type: Application
    Filed: July 17, 2009
    Publication date: November 12, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick Bewlay, Magdi N. Azer, Laurent Cretegny, Ann Melinda Ritter, Craig Douglas Young
  • Ceramic lamps and methods of making same
    Patent number: 7615929
    Abstract: A lamp having a ceramic arc envelope, an end structure coupled to the ceramic arc envelope and extending across an opening in the ceramic arc envelope, where the end structure comprises a passageway communicative with an interior chamber of the ceramic arc envelope is provided. The lamp further includes a molybdenum-rhenium electrode lead extending through and sealed with the passageway. The molybdenum-rhenium electrode lead includes a molybdenum-rhenium alloy. Furthermore, the lamp includes an arc electrode tip coupled to the electrode lead inside the interior chamber.
    Type: Grant
    Filed: June 30, 2005
    Date of Patent: November 10, 2009
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Bruce Alan Knudsen, Mohamed Rahmane, James Anthony Brewer, James Scott Vartuli, Istvan Csanyi, Jozsef Gabeli, Agoston Boroczki, Robert Baranyi
  • Rare earth-based core constructions for casting refractory metal composites, and related processes
    Patent number: 7610945
    Abstract: A method of fabricating a core for a ceramic shell mold is disclosed. A porous core body is formed from at least about 50% by weight of at least one rare earth metal oxide. The core body is heated under heating conditions sufficient to provide the core with a density of about 35% to about 80% of its theoretical density. The core body is then infiltrated with a liquid colloid or solution of at least one metal oxide compound, e.g., rare earth metal oxides; silica, aluminum oxide, transition metal oxides, and combinations thereof. The infiltrated core body is then heated to sinter the particles without substantially changing the dimensions of the core body. Mold-core assemblies which include such a core body are also described. A description of processes for casting a turbine component, using the core, is also set forth herein.
    Type: Grant
    Filed: September 29, 2006
    Date of Patent: November 3, 2009
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Frederic Joseph Klug
  • Methods for reducing carbon contamination when melting highly reactive alloys
    Patent number: 7582133
    Abstract: Methods for reducing carbon contamination when melting highly reactive alloys involving providing a graphite crucible having an interior, applying at least a first protective layer to the interior of the graphite crucible, placing a highly reactive alloy into the crucible having the first protective layer, and melting the highly reactive alloy to obtain a melted alloy having reduced carbon contamination.
    Type: Grant
    Filed: December 27, 2006
    Date of Patent: September 1, 2009
    Assignee: General Electric Company
    Inventors: Thomas Joseph Kelly, Michael James Weimer, Bernard Patrick Bewlay, Michael Francis Xavier Gigliotti, Jr.
  • Methods for the formation of refractory metal intermetallic composites, and related articles and compositions
    Patent number: 7575042
    Abstract: A method for forming an article is described. The method includes the step of applying a precursor material to at least one surface of a mold structure for casting the article, and curing the applied precursor material. The precursor material includes facecoat-forming constituents which can be curably converted into a facecoat; and a protective coating-former for the article being cast. Molten material is then introduced into the mold structure, so as to come in contact with the facecoat formed from the cured precursor material. The molten material is cooled, to form the article. The cured precursor material, which is in contact with a surface of the cast article, is then reacted with the article, to form the protective coating on the surface of the article. Related mold structures are also described.
    Type: Grant
    Filed: March 30, 2006
    Date of Patent: August 18, 2009
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Melvin Robert Jackson
  • HAFNIA-MODIFIED RARE-EARTH METAL-BASED CERAMIC BODIES AND CASTING PROCESSES PERFORMED THEREWITH
    Publication number: 20090197758
    Abstract: Compositions suitable for use as cores and shell molds for casting of reactive metal alloys, and casting processes for producing components from such alloys. The composition contains a sintered particulate material of hafnia and at least one additional metal oxide in amounts to yield a ceramic composition containing up to 70 molar percent of hafnia, wherein the additional metal oxide is a rare-earth oxide, the sintered particulate material contains first and second phases, the first phase is the rare-earth oxide and hafnia in solid solution, the second phase is a compound of the rare-earth oxide and hafnia, and the second phase is less reactive with the reactive metal alloy than the first phase.
    Type: Application
    Filed: January 31, 2008
    Publication date: August 6, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Stephen Francis Bancheri, Frederic Joseph Klug, Bernard Patrick Bewlay
  • METHODS FOR THE FORMATION OF REFRACTORY METAL INTERMETALLIC COMPOSITES, AND RELATED ARTICLES AND COMPOSITIONS
    Publication number: 20090178775
    Abstract: A method for forming an article is described. The method includes the step of applying a precursor material to at least one surface of a mold structure for casting the article, and curing the applied precursor material. The precursor material includes facecoat-forming constituents which can be curably converted into a facecoat; and a protective coating-former for the article being cast. Molten material is then introduced into the mold structure, so as to come in contact with the facecoat formed from the cured precursor material. The molten material is cooled, to form the article. The cured precursor material, which is in contact with a surface of the cast article, is then reacted with the article, to form the protective coating on the surface of the article. Related mold structures are also described.
    Type: Application
    Filed: March 30, 2006
    Publication date: July 16, 2009
    Inventors: Bernard Patrick Bewlay, Melvin Robert Jackson
  • REFRACTORY CRUCIBLES CAPABLE OF MANAGING THERMAL STRESS AND SUITABLE FOR MELTING HIGHLY REACTIVE ALLOYS
    Publication number: 20090140473
    Abstract: Refractory crucibles capable of managing thermal stress and suitable for melting highly reactive alloys having a facecoat, a backing, and at least one retaining ring applied about at least a portion of the backing of the crucible, the retaining ring comprising a composition selected from the group consisting of conductive materials, non-conductive materials, and combinations thereof.
    Type: Application
    Filed: November 30, 2007
    Publication date: June 4, 2009
    Inventors: BERNARD PATRICK BEWLAY, Michael Francis Xavier Gigliotti, Mohamed Rahmane, Thomas Joseph Kelly, Michael James Weimer, Sairam Sundaram
  • METHODS FOR MAKING REFRACTORY CRUCIBLES CAPABLE OF MANAGING THERMAL STRESS AND SUITABLE FOR MELTING HIGHLY REACTIVE ALLOYS
    Publication number: 20090139074
    Abstract: Methods for making refractory crucibles capable of managing thermal stresses and suitable for melting highly reactive alloys, the method involving providing a crucible having at least a facecoat and a backing, heating at least one retaining ring, applying the at least one retaining ring about at least a portion of the backing of the crucible; and allowing the at least one retaining ring to cool and shrink-fit about the crucible.
    Type: Application
    Filed: November 30, 2007
    Publication date: June 4, 2009
    Inventors: Bernard Patrick Bewlay, Michael Francis Xavier Gigliotti, Mohamed Rahmane, Thomas Joseph Kelly, Michael James Weimer, Sairam Sundaram
  • METHOD FOR PRODUCING HOMOGENEOUS FINE GRAIN TITANIUM MATERIALS SUITABLE FOR ULTRASONIC INSPECTION
    Publication number: 20090133786
    Abstract: A titanium material production method for producing homogeneous fine grain titanium material in which the titanium material has a grain size in a range from about 5 ?m to about 20 ?m. The method comprises providing a titanium material blank; conducting a first heat treatment on the titanium material blank to heat the titanium material blank to a ?-range; quenching the titanium material blank from the ?-region to the ?+?-region; forging the titanium material blank; and conducting a second heat treatment on the titanium material blank. The titanium material production method subjects the titanium material blank to superplasticity conditions during part of the titanium material production method.
    Type: Application
    Filed: December 29, 2008
    Publication date: May 28, 2009
    Applicant: General Electric Company
    Inventors: Bernard Patrick Bewlay, John Broddus Deaton, JR., Robert Snee Gilmore, Michael Francis Xavier Gigliotti, Gennady A. Salishchev, Oskar A. Kaibyshev
  • HIGH INTENSITY DISCHARGE LAMP HAVING COMPOSITE LEG
    Publication number: 20090079346
    Abstract: A system, in certain embodiments, includes a high intensity discharge lamp having a composite leg. The composite leg includes a plurality of leg sections coupled together in series. The plurality of leg sections includes different materials, coefficients of thermal expansion, Poisson's ratios, or elastic moduli, or a combination thereof. A method, in certain embodiments, includes enclosing a high intensity discharge within a ceramic arc envelope. The method also includes reducing thermal stresses associated with the high intensity discharge via a composite leg extending outwardly from the ceramic arc envelope. The composite leg includes a plurality of leg sections coupled together in series. The plurality of leg sections includes different materials, coefficients of thermal expansion, Poisson's ratios, or elastic moduli, or a combination thereof.
    Type: Application
    Filed: September 20, 2007
    Publication date: March 26, 2009
    Applicant: GENERAL ELECTRIC COMPANY, A NEW YORK CORPORATION
    Inventors: Bernard Patrick Bewlay, Bruce Alan Knudsen, Mohamed Rahmane, James Scott Vartuli, James Anthony Brewer