Patents by Inventor David Paul Mourer
David Paul Mourer 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: 10767246Abstract: A gamma prime nickel-based superalloy is provided, which can include a combination of Ti and Zr in a total weight amount sufficient to form cellular precipitates located at grain boundaries of the alloy, wherein the cellular precipitates define gamma prime arms that distort the grain boundaries at which they are located. The Hf-containing, gamma prime nickel-based superalloy and/or the gamma prime nickel-based superalloy can include cellular precipitates that are predominantly located at grain boundaries of the alloy such that the cellular precipitates define gamma prime arms that distort the grain boundaries at which they are located. The superalloys can further include finer gamma prime precipitates (e.g., cuboidal or spherical precipitates) than the cellular precipitates.Type: GrantFiled: August 17, 2015Date of Patent: September 8, 2020Assignee: General Electric CompanyInventors: David Paul Mourer, Andrew Ezekiel Wessman
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Publication number: 20180223395Abstract: A gamma prime nickel-based superalloy is provided, which can include a combination of Ti and Zr in a total weight amount sufficient to form cellular precipitates located at grain boundaries of the alloy, wherein the cellular precipitates define gamma prime arms that distort the grain boundaries at which they are located. The Hf-containing, gamma prime nickel-based superalloy and/or the gamma prime nickel-based superalloy can include cellular precipitates that are predominantly located at grain boundaries of the alloy such that the cellular precipitates define gamma prime arms that distort the grain boundaries at which they are located. The superalloys can further include finer gamma prime precipitates (e.g., cuboidal or spherical precipitates) than the cellular precipitates.Type: ApplicationFiled: August 17, 2015Publication date: August 9, 2018Inventors: David Paul MOURER, Andrew Ezekiel WESSMAN
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Patent number: 9931815Abstract: Coatings for substrates, such as superalloy substrates, are provided. The coating can include: 15 wt % to 45 wt % cobalt; 20 wt % to 40 wt % chromium; 2 wt % to 15 wt % aluminum; 0.1 wt % to 1 wt % yttrium; and nickel. The coatings may include nickel, cobalt, chromium and aluminum, and other optional additives to improve oxidation and corrosion resistance of the substrate without significant debit to its mechanical properties.Type: GrantFiled: March 12, 2014Date of Patent: April 3, 2018Assignee: General Electric CompanyInventors: David Paul Mourer, Leonardo Ajdelsztajn, Kenneth Rees Bain, Andrew Joseph Detor, Andrew William Emge, James Anthony Ruud, Michael James Weimer
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Patent number: 9518310Abstract: A gamma prime nickel-base superalloy and components formed therefrom that exhibit improved high-temperature dwell capabilities, including creep and hold time fatigue crack growth behavior. A particular example of a component is a powder metallurgy turbine disk of a gas turbine engine. The gamma-prime nickel-base superalloy contains, by weight: 16.0 to 30.0% cobalt; 9.5 to 12.5% chromium; 4.0 to 6.0% tantalum; 2.0 to 4.0% aluminum; 2.0 to 3.4% titanium; 3.0 to 6.0% tungsten; 1.0 to 4.0% molybdenum; 1.5 to 3.5% niobium; up to 1.0% hafnium; 0.02 to 0.20% carbon; 0.01 to 0.05% boron; 0.02 to 0.10% zirconium; the balance essentially nickel and impurities. The superalloy has a W+Nb?Cr value of at least ?6, is free of observable amounts of sigma and eta phases, and exhibits a time to 0.2% creep at 1300° F. and 100 ksi of at least 1000 hours.Type: GrantFiled: July 23, 2013Date of Patent: December 13, 2016Assignee: General Electric CompanyInventors: David Paul Mourer, Richard DiDomizio, Timothy Hanlon, Daniel Yeuching Wei, Andrew Ezekiel Wessman, Kenneth Rees Bain, Andrew Martin Powell
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Publication number: 20160031186Abstract: Coatings for substrates, such as superalloy substrates, are provided. The coating can include: 15 wt % to 45 wt % cobalt; 20 wt % to 40 wt % chromium; 2 wt % to 15 wt % aluminum; 0.1 wt % to 1 wt % yttrium; and nickel. The coatings may include nickel, cobalt, chromium and aluminum, and other optional additives to improve oxidation and corrosion resistance of the substrate without significant debit to its mechanical properties.Type: ApplicationFiled: March 12, 2014Publication date: February 4, 2016Inventors: David Paul MOURER, Leonardo AJDELSZTAJN, Kenneth Rees BAIN, Andrew Joseph DETOR, Andrew William EMGE, James Anthony RUUD, Michael James WEIMER
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Patent number: 9156113Abstract: Processes for fabricating components to have two or more regions with different grain structures, and components produced by such processes. The processes entail performing at least one forging step on a preform to produce a profile having at least a first portion corresponding to the first region of the component. The preform is formed of a precipitation-strengthened alloy having a solvus temperature, and the at least one forging step comprises a nonfinal forging step performed at a first strain rate and at a first subsolvus temperature that is below the solvus temperature of the alloy. A subsequent forging step is performed on the profile to produce a final profile comprising the first portion and a second portion corresponding to the second region of the component.Type: GrantFiled: June 3, 2011Date of Patent: October 13, 2015Assignee: General Electric CompanyInventors: Andrew Ezekiel Wessman, David Paul Mourer, Daniel Yeuching Wei
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Publication number: 20150167123Abstract: A gamma prime nickel-based superalloy suitable for producing structural components (10), for example, turbine disks (10) and other turbomachinery components. The superalloy comprises an intentional amount of iron of up to 2.0% and is preferably capable of exhibiting structural properties comparable to nickel-based superalloys without iron. The superalloy can be made using processes that lend themselves to advantageous scrap and revert usage of iron-containing alloys. The superalloy is free of an observable amount of sigma phase.Type: ApplicationFiled: July 11, 2013Publication date: June 18, 2015Inventors: Michael Leslie Lasonde, David Paul Mourer, Joseph Aloysius Heaney III
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Patent number: 8992700Abstract: A gamma prime nickel-base superalloy and components formed therefrom that exhibit improved high-temperature dwell capabilities, including creep and hold time fatigue crack growth behavior. A particular example of a component is a powder metallurgy turbine disk of a gas turbine engine. The gamma-prime nickel-base superalloy contains, by weight, 18.0 to 30.0% cobalt, 11.4 to 16.0% chromium, up to 6.0% tantalum, 2.5 to 3.5% aluminum, 2.5 to 4.0% titanium, 5.5 to 7.5% molybdenum, up to 2.0% niobium, up to 2.0% hafnium, 0.04 to 0.20% carbon, 0.01 to 0.05% boron, 0.03 to 0.09% zirconium, the balance essentially nickel and impurities, wherein the titanium:aluminum weight ratio is 0.71 to 1.60.Type: GrantFiled: May 29, 2009Date of Patent: March 31, 2015Assignee: General Electric CompanyInventors: Kenneth Rees Bain, David Paul Mourer, Richard DiDomizio, Timothy Hanlon, Laurent Cretegny, Andrew Ezekiel Wessman
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Patent number: 8992699Abstract: A gamma prime nickel-base superalloy and components formed therefrom that exhibit improved high-temperature dwell capabilities, including creep and hold time fatigue crack growth behavior. A particular example of a component is a powder metallurgy turbine disk of a gas turbine engine. The gamma-prime nickel-base superalloy contains, by weight, 16.0 to 30.0% cobalt, 11.5 to 15.0% chromium, 4.0 to 6.0% tantalum, 2.0 to 4.0% aluminum, 1.5 to 6.0% titanium, up to 5.0% tungsten, 1.0 to 7.0% molybdenum, up to 3.5% niobium, up to 1.0% hafnium, 0.02 to 0.20% carbon, 0.01 to 0.05% boron, 0.02 to 0.10% zirconium, the balance essentially nickel and impurities, wherein the titanium:aluminum weight ratio is 0.5 to 2.0.Type: GrantFiled: May 29, 2009Date of Patent: March 31, 2015Assignee: General Electric CompanyInventors: Kenneth Rees Bain, David Paul Mourer, Richard DiDomizio, Timothy Hanlon, Laurent Cretegny, Andrew Ezekiel Wessman
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Patent number: 8918996Abstract: Processes for fabricating components to have two or more regions with different grain structures, and components produced by such processes. First and second preforms are fabricated to comprise interface surfaces at which the preforms can be joined together. The first and second preforms are formed of first and second precipitation-strengthened alloys, respectively, and the first alloy differs from the second alloy by having a higher solvus temperature or a higher grain refiner content. The preforms are joined together to form an article comprising first and second portions formed by the first and second preforms, respectively, and corresponding to first and second regions of the component, respectively, and the interface surfaces of the preforms form a joint between the first and second portions of the article. A supersolvus heat treatment is performed on the article so that greater grain growth occurs in the second portion than in the first portion.Type: GrantFiled: May 4, 2011Date of Patent: December 30, 2014Assignee: General Electric CompanyInventors: Andrew Ezekiel Wessman, David Paul Mourer
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Publication number: 20140205449Abstract: A gamma prime nickel-base superalloy and components formed therefrom that exhibit improved high-temperature dwell capabilities, including creep and hold time fatigue crack growth behavior. A particular example of a component is a powder metallurgy turbine disk of a gas turbine engine. The gamma-prime nickel-base superalloy contains, by weight: 16.0 to 30.0% cobalt; 9.5 to 12.5% chromium; 4.0 to 6.0% tantalum; 2.0 to 4.0% aluminum; 2.0 to 3.4% titanium; 3.0 to 6.0% tungsten; 1.0 to 4.0% molybdenum; 1.5 to 3.5% niobium; up to 1.0% hafnium; 0.02 to 0.20% carbon; 0.01 to 0.05% boron; 0.02 to 0.10% zirconium; the balance essentially nickel and impurities. The superalloy has a W+Nb?Cr value of at least ?6, is free of observable amounts of sigma and eta phases, and exhibits a time to 0.2% creep at 1300° F. and 100 ksi of at least 1000 hours.Type: ApplicationFiled: July 23, 2013Publication date: July 24, 2014Applicant: General Electric CompanyInventors: David Paul Mourer, Richard DiDomizio, Timothy Hanlon, Daniel Yeuching Wei, Andrew Ezekiel Wessman, Kenneth Rees Bain, Andrew Martin Powell
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Patent number: 8636195Abstract: A process of fabricating a rotating component and a rotating component formed thereby. The rotating component has a rotational axis, at least one rim member, at least one disk member, and at least one airfoil member. The rim and disk members are welded together to define a first solid-state weld joint lying in a first plane that is not parallel to the rotational axis of the rotating component. The airfoil member is welded to the rim member to define a second solid-state weld joint lying in a second plane that is not parallel to the rotational axis of the rotating component. The rim member is located in a radially outward direction from the disk member, and the airfoil member is located in a radially outward direction from the rim member.Type: GrantFiled: February 19, 2010Date of Patent: January 28, 2014Assignee: General Electric CompanyInventors: Douglas Gerard Konitzer, Eric Scott Huron, David Paul Mourer, Brian James Girvin, Glenn Charles Culbertson, Daniel Edward Wines, Daniel David Noe
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Patent number: 8613810Abstract: A gamma prime nickel-base superalloy and components formed therefrom that exhibit improved high-temperature dwell capabilities, including creep and dwell fatigue crack growth behavior. The superalloy contains, by weight, 10.00 to 22.0% cobalt, 10.0 to 14.0% chromium, 4.0 to 6.0% tantalum, 2.0 to 4.0% aluminum, 2.0 to 6.0% titanium, 1.5 to 5.0% tungsten, 1.5 to 5.0% molybdenum, 1.0 to 3.5% niobium, 0.05 to 0.6% hafnium, 0.02 to 0.10% carbon, 0.01 to 0.40% boron, 0.02 to 0.10% zirconium, the balance essentially nickel and impurities, wherein the titanium:aluminum weight ratio is 0.7 to 1.5. The superalloy is hot worked and heat treated to contain cellular gamma prime precipitates that distort grain boundaries, creating tortuous grain boundary fracture paths that are believed to promote the fatigue crack growth resistance of the superalloy.Type: GrantFiled: May 3, 2011Date of Patent: December 24, 2013Assignee: General Electric CompanyInventors: David Paul Mourer, Kenneth Rees Bain
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Patent number: 8480368Abstract: A process of fabricating a rotating component and components formed thereby. The process includes fabricating preforms corresponding to portions of the component. Each preform has an interface surface at which the preforms can be joined to locate a first of the portions in a radially outward direction from a second of the portions. The preforms are then inertia welded together to form a profile having a solid-state weld joint containing a finer-grained material than other portions of the profile. The profile is then forged with dies to produce a forging. At least one of the dies has a recess into which the finer-grained material from the weld joint is expelled during forging to purge a joint region of the forging between the forging portions of the finer-grained material. The joint region contains grains distorted in an axial direction of the forging.Type: GrantFiled: February 5, 2010Date of Patent: July 9, 2013Assignee: General Electric CompanyInventors: Ronald Gene Tolbert, Eric Scott Huron, David Paul Mourer, Douglas Gerard Konitzer
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Publication number: 20120305143Abstract: Processes for fabricating components to have two or more regions with different grain structures, and components produced by such processes. The processes entail performing at least one forging step on a preform to produce a profile having at least a first portion corresponding to the first region of the component. The preform is formed of a precipitation-strengthened alloy having a solvus temperature, and the at least one forging step comprises a nonfinal forging step performed at a first strain rate and at a first subsolvus temperature that is below the solvus temperature of the alloy. A subsequent forging step is performed on the profile to produce a final profile comprising the first portion and a second portion corresponding to the second region of the component.Type: ApplicationFiled: June 3, 2011Publication date: December 6, 2012Applicant: GENERAL ELECTRIC COMPANYInventors: Andrew Ezekiel Wessman, David Paul Mourer, Daniel Yeuching Wei
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Publication number: 20120279067Abstract: Processes for fabricating components to have two or more regions with different grain structures, and components produced by such processes. First and second preforms are fabricated to comprise interface surfaces at which the preforms can be joined together. The first and second preforms are formed of first and second precipitation-strengthened alloys, respectively, and the first alloy differs from the second alloy by having a higher solvus temperature or a higher grain refiner content. The preforms are joined together to form an article comprising first and second portions formed by the first and second preforms, respectively, and corresponding to first and second regions of the component, respectively, and the interface surfaces of the preforms form a joint between the first and second portions of the article. A supersolvus heat treatment is performed on the article so that greater grain growth occurs in the second portion than in the first portion.Type: ApplicationFiled: May 4, 2011Publication date: November 8, 2012Applicant: GENERAL ELECTRIC COMPANYInventors: Andrew Ezekiel Wessman, David Paul Mourer
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Publication number: 20120051919Abstract: A forging preform for a turbine rotor disk is disclosed. The preform includes a body of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of 10 or smaller. 5. A turbine rotor disk is also disclosed. The disk includes a substantially cylindrical disk of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of about 10 or smaller. A method of making a turbine rotor disk is also disclosed. The method includes providing a superalloy powder material and pressing the superalloy powder material to form a forging preform for a turbine rotor disk.Type: ApplicationFiled: August 31, 2010Publication date: March 1, 2012Applicant: GENERAL ELECTRIC COMPANYInventors: Raymond Joseph Stonitsch, George Albert Goller, Joseph Jay Jackson, David Paul Mourer, Daniel Yeuching Wei
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Publication number: 20110206523Abstract: A process of fabricating a rotating component and a rotating component formed thereby. The rotating component has a rotational axis, at least one rim member, at least one disk member, and at least one airfoil member. The rim and disk members are welded together to define a first solid-state weld joint lying in a first plane that is not parallel to the rotational axis of the rotating component. The airfoil member is welded to the rim member to define a second solid-state weld joint lying in a second plane that is not parallel to the rotational axis of the rotating component. The rim member is located in a radially outward direction from the disk member, and the airfoil member is located in a radially outward direction from the rim member.Type: ApplicationFiled: February 19, 2010Publication date: August 25, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: Douglas Gerard Konitzer, Eric Scott Huron, David Paul Mourer, Brian James Girvin, Glenn Charles Culbertson, Daniel Edward Wines, Daniel David Noe
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Publication number: 20110203707Abstract: A gamma prime nickel-base superalloy and components formed therefrom that exhibit improved high-temperature dwell capabilities, including creep and dwell fatigue crack growth behavior. The superalloy contains, by weight, 10.00 to 22.0% cobalt, 10.0 to 14.0% chromium, 4.0 to 6.0% tantalum, 2.0 to 4.0% aluminum, 2.0 to 6.0% titanium, 1.5 to 5.0% tungsten, 1.5 to 5.0% molybdenum, 1.0 to 3.5% niobium, 0.05 to 0.6% hafnium, 0.02 to 0.10% carbon, 0.01 to 0.40% boron, 0.02 to 0.10% zirconium, the balance essentially nickel and impurities, wherein the titanium:aluminum weight ratio is 0.7 to 1.5. The superalloy is hot worked and heat treated to contain cellular gamma prime precipitates that distort grain boundaries, creating tortuous grain boundary fracture paths that are believed to promote the fatigue crack growth resistance of the superalloy.Type: ApplicationFiled: May 3, 2011Publication date: August 25, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: David Paul Mourer, Kenneth Rees Bain
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Publication number: 20110194940Abstract: A process of fabricating a rotating component and components formed thereby. The process includes fabricating preforms corresponding to portions of the component. Each preform has an interface surface at which the preforms can be joined to locate a first of the portions in a radially outward direction from a second of the portions. The preforms are then inertia welded together to form a profile having a solid-state weld joint containing a finer-grained material than other portions of the profile. The profile is then forged with dies to produce a forging. At least one of the dies has a recess into which the finer-grained material from the weld joint is expelled during forging to purge a joint region of the forging between the forging portions of the finer-grained material. The joint region contains grains distorted in an axial direction of the forging.Type: ApplicationFiled: February 5, 2010Publication date: August 11, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: Ronald Gene Tolbert, Eric Scott Huron, David Paul Mourer, Douglas Gerard Konitzer