Patents by Inventor David John Wortman

David John Wortman 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).

  • Publication number: 20180058228
    Abstract: A gas turbine component for use in a gas turbine engine includes a substrate a ceramic-based thermal barrier coating (TBC), and a diffusion chromide bond coat between the base material and the TBC. A thermally grown oxide (TGO) layer can be formed on the bond coat prior to application of the TBC. The TBC and the TGO include a common metal oxide. The oxide can be sacrificially in use and soluble in a molten sulfate salt, make the coating system particularly suitable for use in a marine environment.
    Type: Application
    Filed: August 25, 2017
    Publication date: March 1, 2018
    Inventors: Charles Clifford BERGER, David John WORTMAN
  • Patent number: 9297089
    Abstract: A gas turbine component for use in a gas turbine engine includes a substrate and a non-aluminide protective coating with a platinum-group metal. The platinum-group metal resides in a gamma-prime phase of the underlying material. The platinum-group metal can impart the protective coating with superior corrosion-resistance, while the absence of aluminide in the protective coating facilitates use of the protective coating at high-stress and/or high-fatigue portions of the component. The protective coating optionally includes chromide and can also be combined with aluminide at select portions of the component.
    Type: Grant
    Filed: July 6, 2012
    Date of Patent: March 29, 2016
    Assignee: Barson Composites Corporation
    Inventors: Charles Clifford Berger, David John Wortman
  • Patent number: 8545185
    Abstract: Turbine airfoil components with protective layers and methods therefore. The components are each formed to have a platform, an airfoil extending upwardly from the platform, and a shank extending downwardly from the platform. The shank has an exterior wall and an internal passage, and the airfoil has a cooling flow channel inside the airfoil for flowing a cooling flow therethrough. The component has an interior chromide coating contacting at least a portion of an interior surface of the shank and interdiffused with a base metal thereof, and an exterior chromide coating contacting at least a portion of an exterior surface of the shank and interdiffused with the base metal thereof. The interior and exterior chromide coatings do not have an aluminide coating deposited thereon.
    Type: Grant
    Filed: December 19, 2007
    Date of Patent: October 1, 2013
    Assignee: General Electric Company
    Inventors: David John Wortman, Roger Dale Wustman, Nicole Marie Polley, Kathleen Diana Brammer, Brian Thomas Hazel
  • Publication number: 20130011270
    Abstract: A gas turbine component for use in a gas turbine engine includes a substrate and a non-aluminide protective coating with a platinum-group metal. The platinum-group metal resides in a gamma-prime phase of the underlying material. The platinum-group metal can impart the protective coating with superior corrosion-resistance, while the absence of aluminide in the protective coating facilitates use of the protective coating at high-stress and/or high-fatigue portions of the component. The protective coating optionally includes chromide and can also be combined with aluminide at select portions of the component.
    Type: Application
    Filed: July 6, 2012
    Publication date: January 10, 2013
    Applicant: BARSON COMPOSITES CORPORATION
    Inventors: Charles Clifford Berger, David John Wortman
  • Publication number: 20090162690
    Abstract: Coating system for a metallic substrate includes a strengthened bond coat including a bond coat inner layer and an aluminum-containing layer overlying the bond coat inner layer. The bond coat inner layer is formed by deposition of a bond coat composition including, in weight percent, 14-20% Cr, 5-8% Al, 8-12% Co, 3-7% Ta, 0.1-0.6% Hf, 0.1-0.5% Y, up to about 1% Si, 0.005-0.020% Zr, 0.04-0.08% C, 0.01-0.02% B, with a remainder including Ni and incidental impurities, wherein the bond coat composition is substantially free of rhenium. The coating system includes an optional thermal barrier coating which may be a yttria-stabilized zirconia.
    Type: Application
    Filed: December 24, 2007
    Publication date: June 25, 2009
    Inventors: Bangalore Aswatha Nagaraj, David John Wortman, Michael Patrick Maly
  • Publication number: 20090162562
    Abstract: Methods for coating a substrate includes depositing on the substrate, a inner bond coat layer of a bond coat composition comprising, in weight percent, 14-20% Cr, 5-8% Al, 8-12% Co, 3-7% Ta, 0.1-0.6% Hf, 0.1-0.5% Y, up to about 1% Si, 0.005-0.020% Zr, 0.04-0.08% C, 0.01-0.02% B, with a remainder including nickel (Ni) and incidental impurities, wherein the bond coat composition is substantially free of rhenium; forming an aluminum-containing layer overlying the inner bond coat layer; and, optionally, depositing a thermal barrier coating composition overlying the aluminum-containing layer.
    Type: Application
    Filed: December 24, 2007
    Publication date: June 25, 2009
    Inventors: Bangalore Aswatha Nagaraj, David John Wortman, Nicole Marie Polley, William Bryan Connor, Roger Dale Wustman
  • Publication number: 20090162209
    Abstract: A gas turbine blade comprises a base metal, a platform, an airfoil extending upwardly from the platform, a shank extending downwardly from the platform. The shank has an exterior wall and an internal passage, and the airfoil has a cooling flow channel inside the airfoil for flowing a cooling flow therethrough. The blade has a first chromide coating contacting the base metal of at least a portion of an interior surface of the shank and interdiffused therewith, wherein the first chromide coating does not have an aluminide coating deposited over it. The blade has a second chromide coating contacting the base metal of at least a portion of an interior surface of the airfoil and interdiffused therewith. A method for preparing a gas turbine blade comprises the steps of applying chromide coatings, sealing the interior passages of the shank and airfoil and applying an aluminide or platinum aluminide coating and an optional ceramic layer on the airfoil.
    Type: Application
    Filed: December 19, 2007
    Publication date: June 25, 2009
    Inventors: DAVID JOHN WORTMAN, Roger Dale Wustman, Nicole Marie Polley, Kathleen Diana Brammer, Brian Thomas Hazel
  • Publication number: 20090162692
    Abstract: Coated superalloy article includes a bond coat comprising an inner bond coat layer disposed on the first surface being formed by deposition of a bond coat composition comprising, in weight percent, 14-20% Cr, 5-8% Al, 8-12% Co, 3-7% Ta, 0.1-0.6% Hf, 0.1-0.5% Y, up to about 1% Si, 0.005-0.020% Zr, 0.04-0.08% C, 0.01-0.02% B, with a remainder including nickel (Ni) and incidental impurities, wherein the bond coating composition is substantially free of rhenium. An aluminum-containing layer overlies the inner bond coat layer. Optionally, a thermal barrier coating overlies the aluminum-containing layer, wherein the thermal barrier coating, if present, is formed by deposition of a thermal barrier coating composition.
    Type: Application
    Filed: December 24, 2007
    Publication date: June 25, 2009
    Inventors: Bangalore Aswatha Nagaraj, David John Wortman, Nicole Marie Polley, William Bryan Connor, Roger Dale Wustman
  • Patent number: 7306859
    Abstract: A coating process and TBC system suitable for protecting the surface of a component subjected to a hostile thermal environment. The TBC system has a first layer with a columnar microstructure, and a second layer on the first layer and with a microstructure characterized by irregular flattened grains. According to one aspect, the first layer is present and the second layer is not present on a first surface portion of the component, and the first and second layers are both present on a second surface portion of the component. According to another aspect, the first and second layers contain the same base ceramic compound.
    Type: Grant
    Filed: January 28, 2005
    Date of Patent: December 11, 2007
    Assignee: General Electric Company
    Inventors: David John Wortman, Jonathan Paul Blank, Sean Robert Keith
  • Patent number: 7250225
    Abstract: An intermetallic composition suitable for use as an environmentally-protective coating on surfaces of components used in hostile thermal environments, including the turbine, combustor and augmentor sections of a gas turbine engine. The coating contains the gamma-prime (Ni3Al) nickel aluminide intermetallic phase and either the beta (NiAl) nickel aluminide intermetallic phase or the gamma solid solution phase. The coating has an average aluminum content of 14 to 30 atomic percent and an average platinum-group metal content of at least 1 to less than 10 atomic percent, the balance of the coating being nickel, incidental impurities, and optionally hafnium.
    Type: Grant
    Filed: September 26, 2005
    Date of Patent: July 31, 2007
    Assignee: General Electric Company
    Inventors: Brian Thomas Hazel, Ramgopal Darolia, Brett Allen Rohrer Boutwell, David John Wortman
  • Patent number: 7247393
    Abstract: An intermetallic composition suitable for use as an environmentally-protective coating on surfaces of components used in hostile thermal environments, including the turbine, combustor and augmentor sections of a gas turbine engine. The coating contains the gamma-prime (Ni3Al) nickel aluminide intermetallic phase and either the beta (NiAl) nickel aluminide intermetallic phase or the gamma solid solution phase. The coating has an average aluminum content of 14 to 30 atomic percent and an average platinum-group metal content of at least 1 to less than 10 atomic percent, the balance of the coating being nickel, one or more of chromium, silicon, tantalum, and cobalt, optionally one or more of hafnium, yttrium, zirconium, lanthanum, and cerium, and incidental impurities.
    Type: Grant
    Filed: September 26, 2005
    Date of Patent: July 24, 2007
    Assignee: General Electric Company
    Inventors: Brian Thomas Hazel, Ramgopal Darolia, Brett Allen Rohrer Boutwell, David John Wortman
  • Patent number: 7087266
    Abstract: A thermal barrier coating, or TBC, and method for forming the TBC. The TBC is formed of a thermal-insulating material that contains yttria-stabilized zirconia (YSZ) alloyed with at least a third oxide. The TBC is formed to also contain elemental carbon, and may potentially contain carbides and/or a carbon-containing gas that forms from the thermal decomposition of carbon. The TBC is characterized by lower density and thermal conductivity, high temperature stability and improved mechanical properties. To exhibit the desired effect, the third oxide is more particularly one that increases the lattice strain energy of the TBC microstructure as a result of having an ion size that is sufficiently different than a zirconium ion.
    Type: Grant
    Filed: June 18, 2004
    Date of Patent: August 8, 2006
    Assignee: General Electric Company
    Inventors: Ramgopal Darolia, Boris A. Movchan, Yuriy E. Rudoy, Leonella M. Nerodenko, Irene Spitsberg, David John Wortman
  • Patent number: 6998172
    Abstract: A thermal barrier coating (TBC 26) and method for forming the TBC (26) on a component (10) characterized by a stabilized microstructure that resists grain growth, sintering and pore coarsening or coalescence during high temperature excursions. The TBC (26) contains elemental carbon and/or a carbon-containing gas that increase the amount of porosity (32) initially within the TBC (26) and form additional fine closed porosity (32) within the TBC (26) during subsequent exposures to high temperatures. A first method involves incorporating elemental carbon precipitates by evaporation into the TBC microstructure. A second method is to directly incorporate an insoluble gas, such as a carbon-containing gas, into an as-deposited TBC (26) and then partially sinter the TBC (26) to entrap the gas and produce fine stable porosity within the TBC (26).
    Type: Grant
    Filed: August 16, 2002
    Date of Patent: February 14, 2006
    Assignee: General Electric Company
    Inventors: Boris A. Movchan, Yuriy E. Rudoy, Leonella M. Nerodenko, Ramgopal Darolia, Irene Spitsberg, Anthony Mark Thompson, Curtis Alan Johnson, David John Wortman
  • Patent number: 6946034
    Abstract: An electron beam physical vapor deposition (EBPVD) apparatus for producing a coating material (e.g., a ceramic thermal barrier coating) on an article. The EBPVD apparatus generally includes a coating chamber that is operable at elevated temperatures and subatmospheric pressures. An electron beam gun projects an electron beam into the coating chamber through an aperture in a wall of the chamber and onto a coating material within a coating region defined within the chamber, causing the coating material to melt and evaporate. An article is supported within the coating chamber so that vapors of the coating material deposit on the article. The operation of the EBPVD apparatus is enhanced by the inclusion within the coating chamber of a second chamber that encloses the aperture so as to separate the aperture from the coating region. The second chamber is maintained at a pressure lower than the coating region.
    Type: Grant
    Filed: August 19, 2003
    Date of Patent: September 20, 2005
    Assignee: General Electric Company
    Inventors: Robert William Bruce, Antonio Frank Maricocchi, Christopher Lee Lagemann, John Douglas Evans, Sr., Keith Humphries Betscher, Rudolfo Viguie, David Vincent Rigney, David John Wortman, William Seth Willen
  • Patent number: 6863937
    Abstract: An electron beam physical vapor deposition (EBPVD) apparatus and a method for using the apparatus to produce a coating material (e.g., a ceramic thermal barrier coating) on an article. The EBPVD apparatus generally includes a coating chamber that is operable at elevated temperatures and subatmospheric pressures. An electron beam gun projects an electron beam into the coating chamber and onto a coating material within the chamber, causing the coating material to melt and evaporate. An article is supported within the coating chamber so that vapors of the coating material deposit on the article. The operation of the EBPVD apparatus is enhanced by the inclusion or adaptation of one or more mechanical and/or process modifications, including those necessary or beneficial when operating the apparatus at coating pressures above 0.010 mbar.
    Type: Grant
    Filed: November 19, 2002
    Date of Patent: March 8, 2005
    Assignee: General Electric Company
    Inventors: Robert William Bruce, Antonio Frank Maricocchi, Christopher Lee Lagemann, John Douglas Evans, Sr., Keith Humphries Betscher, Rudolfo Viguie, David Vincent Rigney, David John Wortman, William Seth Willen
  • Patent number: 6808799
    Abstract: A thermal barrier coating, or TBC (26), and method for forming the TBC (26). The TBC (26) is formed of a thermal-insulating material that contains yttria-stabilized zirconia (YSZ) alloyed with at least a third oxide. The TBC (26) is formed to also contain elemental carbon, and may potentially contain carbides and/or a carbon-containing gas that forms from the thermal decomposition of carbon. The TBC (26) is characterized by lower density and thermal conductivity, high temperature stability and improved mechanical properties. To exhibit the desired effect, the third oxide is more particularly one that increases the lattice strain energy of the TBC microstructure as a result of having an ion size that is sufficiently different than a zirconium ion.
    Type: Grant
    Filed: August 16, 2002
    Date of Patent: October 26, 2004
    Assignee: General Electric Company
    Inventors: Ramgopal Darolia, Boris A. Movchan, Yuriy E. Rudoy, Leonella M. Nerodenko, Irene Spitsberg, David John Wortman
  • Publication number: 20040180252
    Abstract: A fuel cell and a method for manufacturing a fuel cell are presented. The method comprises providing at least one substrate and disposing a plurality of fuel cell component layers on the substrate by at least one physical vapor deposition process. Each layer of the plurality comprises an edge bordering the layer. The fuel cell unit comprises at least one substrate; a plurality of fuel cell component layers disposed on the substrate, wherein each layer of the plurality comprises an edge bordering the layer; and at least one dense layer of material disposed over at least a portion of the edge of at least one fuel cell component layer. The at least one dense layer seals at least the aforementioned portion of the edge.
    Type: Application
    Filed: March 14, 2003
    Publication date: September 16, 2004
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: David John Wortman, Curtis Alan Johnson, Anthony Mark Thompson, Don Mark Lipkin
  • Publication number: 20040018303
    Abstract: An electron beam physical vapor deposition (EBPVD) apparatus and a method for using the apparatus to produce a coating material (e.g., a ceramic thermal barrier coating) on an article. The EBPVD apparatus generally includes a coating chamber that is operable at elevated temperatures and subatmospheric pressures. An electron beam gun projects an electron beam into the coating chamber and onto a coating material within the chamber, causing the coating material to melt and evaporate. An article is supported within the coating chamber so that vapors of the coating material deposit on the article. The operation of the EBPVD apparatus is enhanced by the inclusion or adaptation of one or more mechanical and/or process modifications, including those necessary or beneficial when operating the apparatus at coating pressures above 0.010 mbar.
    Type: Application
    Filed: November 19, 2002
    Publication date: January 29, 2004
    Inventors: Robert William Bruce, Antonio Frank Maricocchi, Christopher Lee Lagemann, John Douglas Evans, Keith Humphries Betscher, Rudolfo Viguie, David Vincent Rigney, David John Wortman, William Seth Willen
  • Publication number: 20030129316
    Abstract: A thermal barrier coating, or TBC (26), and method for forming the TBC (26). The TBC (26) is formed of a thermal-insulating material that contains yttria-stabilized zirconia (YSZ) alloyed with at least a third oxide. The TBC (26) is formed to also contain elemental carbon, and may potentially contain carbides and/or a carbon-containing gas that forms from the thermal decomposition of carbon. The TBC (26) is characterized by lower density and thermal conductivity, high temperature stability and improved mechanical properties. To exhibit the desired effect, the third oxide is more particularly one that increases the lattice strain energy of the TBC microstructure as a result of having an ion size that is sufficiently different than a zirconium ion.
    Type: Application
    Filed: August 16, 2002
    Publication date: July 10, 2003
    Applicant: General Electric Company
    Inventors: Ramgopal Darolia, Boris A. Movchan, Yuriy E. Rudoy, Leonella M. Nerodenko, Irene Spitsberg, David John Wortman
  • Publication number: 20030129378
    Abstract: A thermal barrier coating (TBC 26) and method for forming the TBC (26) on a component (10) characterized by a stabilized microstructure that resists grain growth, sintering and pore coarsening or coalescence during high temperature excursions. The TBC (26) contains elemental carbon and/or a carbon-containing gas that increase the amount of porosity (32) initially within the TBC (26) and form additional fine closed porosity (32) within the TBC (26) during subsequent exposures to high temperatures. A first method involves incorporating elemental carbon precipitates by evaporation into the TBC microstructure. A second method is to directly incorporate an insoluble gas, such as a carbon-containing gas, into an as-deposited TBC (26) and then partially sinter the TBC (26) to entrap the gas and produce fine stable porosity within the TBC (26).
    Type: Application
    Filed: August 16, 2002
    Publication date: July 10, 2003
    Applicant: General Electric Company
    Inventors: Boris A. Movchan, Yuriy E. Rudoy, Leonella M. Nerodenko, Ramgopal Darolia, Irene Spitsberg, Anthony Mark Thompson, Curtis Alan Johnson, David John Wortman