Patents by Inventor Brett Allen Rohrer Boutwell
Brett Allen Rohrer Boutwell 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: 8100083Abstract: A process and apparatus for depositing a ceramic coating, such as a thermal barrier coating (TBC) for a gas turbine engine component. The process deposits a coating whose composition includes multiple oxide compounds and a carbon-based constituent, e.g., elemental carbon, carbides, and carbon-based gases. The process uses at least one evaporation source to provide multiple different oxide compounds and at least one carbide compound comprising carbon and an element. The evaporation source is evaporated to produce a vapor cloud that contacts and condenses on the component surface to form the ceramic coating, and particularly so that the coating comprises the oxide compounds, an oxide of the element of the carbide compound, and the carbide compound and/or a carbon-containing gas. The process is carried out with an apparatus comprising a coating chamber in which the evaporation source is present, and a device for evaporating the evaporation source.Type: GrantFiled: September 16, 2010Date of Patent: January 24, 2012Assignee: General Electric CompanyInventors: Ramgopal Darolia, Irene Spitsberg, Brett Allen Rohrer Boutwell
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Patent number: 8084094Abstract: A coating process for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating process forms a coating system that includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.Type: GrantFiled: May 14, 2009Date of Patent: December 27, 2011Assignee: General Electric CompanyInventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
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Patent number: 7910173Abstract: A thermal barrier coating and deposition process for a component intended for use in a hostile thermal environment, such as the turbine, combustor and augmentor components of a gas turbine engine. The TBC has a first coating portion on at least a first surface portion of the component. The first coating portion is formed of a ceramic material to have at least an inner region, at least an outer region overlying the inner region, and a columnar microstructure whereby the inner and outer regions comprise columns of the ceramic material. The columns of the inner region are more closely spaced than the columns of the outer region so that the inner region of the first coating portion is denser than the outer region of the first coating portion, wherein the higher density of the inner region promotes the impact resistance of the first coating portion.Type: GrantFiled: July 31, 2008Date of Patent: March 22, 2011Assignee: General Electric CompanyInventors: Irene Spitsberg, Brett Allen Rohrer Boutwell, Robert William Bruce, Curtis Alan Johnson, Bangalore Aswatha Nagaraj, William Scott Walston, Rudolfo Viguie, Joshua Leigh Miller, Roger Dale Wustman
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Patent number: 7867575Abstract: A method for producing a thermal barrier coating/environmental barrier coating system on a silicon containing material substrate includes applying an environmental barrier coating (EBC) over the silicon containing material substrate; and applying a thermal barrier coating (TBC) over the EBC. The thermal barrier coating includes a compound having a primary constituent portion and a stabilizer portion stabilizing said primary constituent. The primary constituent portion of the thermal barrier coating includes hafnia present in an amount of at least about 5 mol % of the primary constituent and the stabilizer portion of said thermal barrier coating includes at least one metal oxide comprised of cations with a +2 or +3 valence present in the amount of about 10 to about 40 mol % of the thermal barrier coating.Type: GrantFiled: October 23, 2007Date of Patent: January 11, 2011Assignee: General Electric CompanyInventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel
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Publication number: 20110003075Abstract: A process and apparatus for depositing a ceramic coating, such as a thermal barrier coating (TBC) for a gas turbine engine component. The process deposits a coating whose composition includes multiple oxide compounds and a carbon-based constituent, e.g., elemental carbon, carbides, and carbon-based gases. The process uses at least one evaporation source to provide multiple different oxide compounds and at least one carbide compound comprising carbon and an element. The evaporation source is evaporated to produce a vapor cloud that contacts and condenses on the component surface to form the ceramic coating, and particularly so that the coating comprises the oxide compounds, an oxide of the element of the carbide compound, and the carbide compound and/or a carbon-containing gas. The process is carried out with an apparatus comprising a coating chamber in which the evaporation source is present, and a device for evaporating the evaporation source.Type: ApplicationFiled: September 16, 2010Publication date: January 6, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: Ramgopal Darolia, Irene Spitsberg, Brett Allen Rohrer Boutwell
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Publication number: 20100291302Abstract: A protected article is prepared by providing the article, depositing a bond coat onto an exposed surface of the article, and producing a thermal barrier coating on an exposed surface of the bond coat. The step of producing the thermal barrier coating includes the steps of depositing a primary ceramic coating onto an exposed surface of the bond coat, and depositing a stabilization composition onto an exposed surface of the primary ceramic coating. The stabilization composition includes a first element selected from Group 2 or Group 3 of the periodic table, and a second element selected from Group 5 of the periodic table. The atomic ratio of the amount of the first element to the amount of the second element is at least 1.3, more preferably at least 1:1.Type: ApplicationFiled: March 12, 2007Publication date: November 18, 2010Applicant: GENERAL ELECTRIC COMPANYInventors: John Frederick Ackerman, Venkat Subramanian Venkataramani, Irene T. Spitsberg, Brett Allen Rohrer Boutwell, Ramgopal Darolia
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Patent number: 7824744Abstract: A process and apparatus for depositing a ceramic coating, such as a thermal barrier coating (TBC) for a gas turbine engine component. The process deposits a coating whose composition includes multiple oxide compounds and a carbon-based constituent, e.g., elemental carbon, carbides, and carbon-based gases. The process uses at least one evaporation source to provide multiple different oxide compounds and at least one carbide compound comprising carbon and an element. The evaporation source is evaporated to produce a vapor cloud that contacts and condenses on the component surface to form the ceramic coating, and particularly so that the coating comprises the oxide compounds, an oxide of the element of the carbide compound, and the carbide compound and/or a carbon-containing gas. The process is carried out with an apparatus comprising a coating chamber in which the evaporation source is present, and a device for evaporating the evaporation source.Type: GrantFiled: December 16, 2003Date of Patent: November 2, 2010Assignee: General Electric CompanyInventors: Ramgopal Darolia, Irene Spitsberg, Brett Allen Rohrer Boutwell
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Patent number: 7597966Abstract: A thermal barrier coating and deposition process for a component intended for use in a hostile thermal environment, such as the turbine, combustor and augmentor components of a gas turbine engine. The TBC has a first coating portion on at least a first surface portion of the component. The first coating portion is formed of a ceramic material to have at least an inner region, at least an outer region overlying the inner region, and a columnar microstructure whereby the inner and outer regions comprise columns of the ceramic material. The columns of the inner region are more closely spaced than the columns of the outer region so that the inner region of the first coating portion is denser than the outer region of the first coating portion, wherein the higher density of the inner region promotes the impact resistance of the first coating portion.Type: GrantFiled: June 10, 2005Date of Patent: October 6, 2009Assignee: General Electric CompanyInventors: Irene Spitsberg, Brett Allen Rohrer Boutwell, Robert William Bruce, Curtis Alan Johnson, Bangalore Aswatha Nagaraj, William Scott Walston
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Publication number: 20090220684Abstract: A coating process for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating process forms a coating system that includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.Type: ApplicationFiled: May 14, 2009Publication date: September 3, 2009Applicant: GENERAL ELECTRIC COMPANYInventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
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Patent number: 7544424Abstract: A coating process and system for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating system includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.Type: GrantFiled: November 30, 2006Date of Patent: June 9, 2009Assignee: General Electric CompanyInventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
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Patent number: 7544394Abstract: In accordance with an embodiment of the invention, an article is provided. The article comprises a substrate comprised of silicon containing material, an environmental barrier coating (EBC) overlying the substrate and a thermal barrier coating (TBC) on the environmental barrier coating. The thermal barrier coating comprising a compound having a rhombohedral phase.Type: GrantFiled: September 5, 2007Date of Patent: June 9, 2009Assignee: General Electric CompanyInventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel, Ramgopal Darolia, Curtis Alan Johnson, Yan Gao, Mark Daniel Gorman
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Patent number: 7537806Abstract: In accordance with an embodiment of the invention, a thermal barrier coating for inclusion in a thermal barrier coating system is provided. The thermal barrier coating comprises a compound having a rhombohedral phase. In accordance with another embodiment of the invention, a thermal barrier coating is provided that comprises a compound having the formula of: A4B3O12, wherein A is at least one rare earth element; and B is selected from the group consisting of Zr, Hf and mixtures thereof.Type: GrantFiled: September 5, 2007Date of Patent: May 26, 2009Assignee: General Electric CompanyInventors: Brett Allen Rohrer Boutwell, Ramgopal Darolia, Curtis Alan Johnson, Irene Spitsberg, Mark Daniel Gorman, Yan Gao
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Patent number: 7476453Abstract: In accordance with an embodiment of the invention, a thermal barrier coating for inclusion in a thermal barrier coating system is provided. The thermal barrier coating comprises a compound having a rhombohedral phase. In accordance with another embodiment of the invention, a thermal barrier coating is provided that comprises a compound having the formula of: A4B3O12, wherein A is at least one rare earth element; and B is selected from the group consisting of Zr, Hf and mixtures thereof.Type: GrantFiled: December 6, 2004Date of Patent: January 13, 2009Assignee: General Electric CompanyInventors: Brett Allen Rohrer Boutwell, Ramgopal Darolia, Curtis Alan Johnson, Irene Spitsberg, Mark Daniel Gorman, Yan Gao
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Publication number: 20080305264Abstract: A thermal barrier coating and deposition process for a component intended for use in a hostile thermal environment, such as the turbine, combustor and augmentor components of a gas turbine engine. The TBC has a first coating portion on at least a first surface portion of the component. The first coating portion is formed of a ceramic material to have at least an inner region, at least an outer region overlying the inner region, and a columnar microstructure whereby the inner and outer regions comprise columns of the ceramic material. The columns of the inner region are more closely spaced than the columns of the outer region so that the inner region of the first coating portion is denser than the outer region of the first coating portion, wherein the higher density of the inner region promotes the impact resistance of the first coating portion.Type: ApplicationFiled: July 31, 2008Publication date: December 11, 2008Applicant: GENERAL ELECTRIC COMPANYInventors: Irene Spitsberg, Brett Allen Rohrer Boutwell, Robert William Bruce, Curtis Alan Johnson, Bangalore Aswatha Nagaraj, William Scott Walston, Rudolfo Viguie, Joshua Leigh Miller, Roger D. Wustman
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Patent number: 7429424Abstract: In accordance with an embodiment of the invention, a thermal barrier coating (TBC) for inclusion in a thermal barrier coating/environmental barrier coating system (TBC/EBC system) for use on a silicon containing material substrate is provided. The TBC comprises a compound having a primary constituent portion and a stabilizer portion stabilizing said primary constituent. The primary constituent portion of the TBC comprises hafnia present in an amount of at least about 5 mol % of the primary constituent. The stabilizer portion of said thermal barrier coating comprises at least one metal oxide comprised of cations with a +2 or +3 valence present in the amount of about 10 to about 40 mol % of the thermal barrier coating.Type: GrantFiled: December 6, 2004Date of Patent: September 30, 2008Assignee: General Electric CompanyInventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel
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Publication number: 20080220172Abstract: In accordance with an embodiment of the invention, a thermal barrier coating (TBC) for inclusion in a thermal barrier coating/environmental barrier coating system (TBC/EBC system) for use on a silicon containing material substrate is provided. The TBC comprises a compound having a primary constituent portion and a stabilizer portion stabilizing said primary constituent. The primary constituent portion of the TBC comprises hafnia present in an amount of at least about 5 mol % of the primary constituent. The stabilizer portion of said thermal barrier coating comprises at least one metal oxide comprised of cations with a +2 or +3 valence present in the amount of about 10 to about 40 mol % of the thermal barrier coating.Type: ApplicationFiled: October 23, 2007Publication date: September 11, 2008Inventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel
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Publication number: 20080166499Abstract: In accordance with an embodiment of the invention, a thermal barrier coating for inclusion in a thermal barrier coating system is provided. The thermal barrier coating comprises a compound having a rhombohedral phase. In accordance with another embodiment of the invention, a thermal barrier coating is provided that comprises a compound having the formula of: A4B3O12, wherein A is at least one rare earth element; and B is selected from the group consisting of Zr, Hf and mixtures thereof.Type: ApplicationFiled: September 5, 2007Publication date: July 10, 2008Inventors: Brett Allen Rohrer Boutwell, Ramgopal Darolia, Curtis Alan Johnson, Irene Spitsberg, Mark Daniel Gorman, Yan Gao
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Publication number: 20080160201Abstract: In accordance with an embodiment of the invention, an article is provided. The article comprises a substrate comprised of silicon containing material, an environmental barrier coating (EBC) overlying the substrate and a thermal barrier coating (TBC) on the environmental barrier coating. The thermal barrier coating comprising a compound having a rhombohedral phase.Type: ApplicationFiled: September 5, 2007Publication date: July 3, 2008Inventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel, Ramgopal Darolia, Curtis Alan Johnson, Yan Gao, Mark Daniel Gorman
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Publication number: 20080131720Abstract: A coating process and system for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating system includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.Type: ApplicationFiled: November 30, 2006Publication date: June 5, 2008Applicant: GENERAL ELECTRIC COMPANYInventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
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Patent number: 7364807Abstract: In accordance with an embodiment of the invention, an article is provided. The article comprises a substrate comprised of silicon containing material, an environmental barrier coating (EBC) overlying the substrate and a thermal barrier coating (TBC) on the environmental barrier coating. The thermal barrier coating comprising a compound having a rhombohedral phase.Type: GrantFiled: December 6, 2004Date of Patent: April 29, 2008Assignee: General Electric CompanyInventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel, Ramgopal Darolia, Curtis Alan Johnson, Yan Gao, Mark Daniel Gorman