Patents by Inventor Dennis William Cavanaugh

Dennis William Cavanaugh 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).

  • Patent number: 9518325
    Abstract: A process of treating a coated article and a treated article are disclosed. The process includes providing an article having a MCrAlY coating, applying an aluminide treatment onto the MCrAlY coating to form a treated MCrAlY coating, and outwardly forming ?-phase material from the MCrAlY coating into the treatment. The applying is selected from the group consisting of soaking, spraying, brushing, dipping, pouring, pack cementation, vapor deposition, and combinations thereof. The treated article includes a substrate and a treated MCrAlY coating positioned on at least a portion of the substrate. The treated MCrAlY coating includes a ?-phase aluminide in a spray-applied, brush-applied, pour-applied, dip-applied, pack cement-applied, vapor deposit-applied, or soaking-applied treatment.
    Type: Grant
    Filed: March 19, 2013
    Date of Patent: December 13, 2016
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: David Vincent Bucci, Dennis William Cavanaugh
  • Patent number: 9222164
    Abstract: In one embodiment, a method for forming an article with a diffusion portion comprises: forming a slurry comprising chromium and silicon, applying the slurry to the article, and heating the article to a sufficient temperature and for a sufficient period of time to diffuse chromium and silicon into the article and form a diffusion portion comprising silicon and a microstructure comprising ?-chromium. In one embodiment, a gas turbine component comprises: a superalloy and a diffusion portion having a depth of less than or equal to 60 ?m measured from the superalloy surface into the gas turbine component. The diffusion portion has a diffusion surface having a microstructure comprising greater than or equal to 40% by volume ?-chromium.
    Type: Grant
    Filed: September 6, 2011
    Date of Patent: December 29, 2015
    Assignee: General Electric Company
    Inventors: David Andrew Helmick, Dennis William Cavanaugh, Ganjiang Feng, David Vincent Bucci
  • Patent number: 9187816
    Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.
    Type: Grant
    Filed: November 6, 2012
    Date of Patent: November 17, 2015
    Assignee: General Electric Company
    Inventors: Stephen Gerard Pope, Dennis William Cavanaugh, John Gregory Obeirne, Eric Eicher McConnell, Mark Lawrence Hunt, Canan Hardwicke
  • Patent number: 8973808
    Abstract: A method for making a cellular seal member for a turbine is disclosed. The method includes, in sequence, forming a diffusion aluminide coating on a surface of a cellular seal to form a coated cellular seal. The method also includes brazing the coated cellular seal to a seal substrate.
    Type: Grant
    Filed: January 5, 2012
    Date of Patent: March 10, 2015
    Assignee: General Electric Company
    Inventors: Dechao Lin, Dennis William Cavanaugh, Yan Cui, Srikanth Chandrudu Kottilingam, Brian Lee Tollison
  • Patent number: 8916005
    Abstract: A slurry and slurry coating process for forming a diffusion aluminide coating on a substrate, including internal surfaces within the substrate. The process involves preparing a slurry of a powder containing a metallic aluminum alloy having a melting temperature higher than aluminum, an activator capable of forming a reactive halide vapor with the metallic aluminum, and a binder containing an organic polymer. The slurry is applied to surfaces of the substrate, which is then heated to burn off the binder, vaporize and react the activator with the metallic aluminum to form the halide vapor, react the halide vapor at the substrate surfaces to deposit aluminum on the surfaces, and diffuse the deposited aluminum into the surfaces to form a diffusion aluminide coating. The process can be tailored to selectively produce an inward or outward-type coating. The binder burns off to form an ash residue that can be readily removed.
    Type: Grant
    Filed: November 15, 2007
    Date of Patent: December 23, 2014
    Assignee: General Electric Company
    Inventors: Dennis William Cavanaugh, Canan Uslu Hardwicke, Matthew James OConnell, Todd Steven Moran
  • Publication number: 20140287260
    Abstract: A process of treating a coated article and a treated article are disclosed. The process includes providing an article having a MCrAlY coating, applying an aluminide treatment onto the MCrAlY coating to form a treated MCrAlY coating, and outwardly forming ?-phase material from the MCrAlY coating into the treatment. The applying is selected from the group consisting of soaking, spraying, brushing, dipping, pouring, pack cementation, vapor deposition, and combinations thereof. The treated article includes a substrate and a treated MCrAlY coating positioned on at least a portion of the substrate. The treated MCrAlY coating includes a ?-phase aluminide in a spray-applied, brush-applied, pour-applied, dip-applied, pack cement-applied, vapor deposit-applied, or soaking-applied treatment.
    Type: Application
    Filed: March 19, 2013
    Publication date: September 25, 2014
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: David Vincent BUCCI, Dennis William CAVANAUGH
  • Publication number: 20140124100
    Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.
    Type: Application
    Filed: November 6, 2012
    Publication date: May 8, 2014
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Stephen Gerard Pope, Dennis William Cavanaugh, John Gregory Obeirne, Eric Eicher McConnell, Mark Lawrence Hunt, Canan Hardwicke
  • Patent number: 8714233
    Abstract: A casting process for producing metal alloy castings, facecoats and apparatuses suitable for carrying out the process, and castings produced by the process. The casting process entails the use of a mold having a cavity with a continuous aluminum-containing solid facecoat on its surface. A molten quantity of a metal alloy is introduced into the mold cavity so that the molten alloy contacts the solid facecoat. The mold is then allowed to cool to solidify the molten alloy and form a cast product. During the casting process, aluminum in the solid facecoat diffuses into the cast product to form an aluminum-containing surface region at the casting surface. Following removal of the cast product from the mold, an alumina-containing scale grows on the casting surface as a result of oxidation of the casting surface region.
    Type: Grant
    Filed: March 29, 2011
    Date of Patent: May 6, 2014
    Assignee: General Electric Company
    Inventors: George Albert Goller, Dennis William Cavanaugh
  • Publication number: 20130175325
    Abstract: A method for making a cellular seal member for a turbine is disclosed. The method includes, in sequence, forming a diffusion aluminide coating on a surface of a cellular seal to form a coated cellular seal. The method also includes brazing the coated cellular seal to a seal substrate.
    Type: Application
    Filed: January 5, 2012
    Publication date: July 11, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Dechao Lin, Dennis William Cavanaugh, Yan Cui, Srikanth Chandrudu Kottilingam, Brian Lee Tollison
  • Publication number: 20130017069
    Abstract: Disclosed is a turbine, a turbine seal structure, and a process of servicing a turbine. The turbine includes the seal structure. The seal structure is mechanically secured within the hot gas path of the turbine. The process of servicing includes positioning the seal structure within the hot gas path of the turbine and mechanically securing the seal structure within the turbine.
    Type: Application
    Filed: July 13, 2011
    Publication date: January 17, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: George Albert GOLLER, Dennis William CAVANAUGH, Matthew LAYLOCK
  • Publication number: 20130017071
    Abstract: Disclosed is a foam structure, a process of fabricating the foam structure, and a turbine including the foam structure. The foam structure includes a cast metallic foam having pores and a gel positioned within at least a portion of the pores. The process of fabricating the foam structure includes providing the cast metallic and infusing the cast metal foam with the gel. The turbine includes a rotating portion and a turbine seal including the foam structure.
    Type: Application
    Filed: July 13, 2011
    Publication date: January 17, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: George Albert GOLLER, Dennis William CAVANAUGH
  • Publication number: 20130017070
    Abstract: Provided is a turbine seal, a turbine, and a process of fabricating a turbine seal. The turbine seal includes a metallic foam positioned along a hot gas path of a turbine. The turbine includes a blade configured to rotate along a predetermined path in response to a hot gas and a metallic foam turbine seal positioned to be contacted by the hot gas. The process of fabricating the turbine seal includes providing a blade configured to rotate along a predetermined path in response to a hot gas and positioning a metallic foam turbine seal to be contacted by the hot gas.
    Type: Application
    Filed: July 13, 2011
    Publication date: January 17, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: George Albert GOLLER, Dennis William CAVANAUGH, Matthew LAYLOCK
  • Publication number: 20120324902
    Abstract: A method and coating for maintaining surface-related properties of a gas turbine combustor component having a wall formed of a nickel-base alloy containing a gamma prime precipitate strengthening phase, interior and exterior surfaces defined by the wall, and at least one hole in the wall that fluidically connects the interior and exterior surfaces of the combustor component. A diffusion coating composition is applied at least within the hole, and then heated to form a diffusion aluminide coating in at least an in-wall surface region of the wall that surrounds and defines the hole. The aluminiding coating forms a diffusion zone that contains a sufficient amount of aluminum intermetallics to inhibit depletion of the gamma prime precipitates in the wall and inhibit degradation and cracking in the in-wall surface region surrounding the hole.
    Type: Application
    Filed: June 27, 2011
    Publication date: December 27, 2012
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Stephen Gerard Pope, Dennis William Cavanaugh
  • Patent number: 8318251
    Abstract: A method and composition are provided for coating honeycomb seals and, more specifically, to a method and slurry for applying an aluminide coating onto honeycomb seals. The method includes preparing a slurry of a powder containing a metallic aluminum alloy having a melting temperature higher than aluminum, an activator capable of forming a reactive halide vapor with the metallic aluminum, and a binder containing an organic polymer. The slurry is applied to surfaces of the honeycomb seal, which is then heated to remove or burn off the binder, vaporize and react the activator with the metallic aluminum to form the halide vapor, react the halide vapor at the substrate surfaces to deposit aluminum on the surfaces of the seal, and diffuse the deposited aluminum into the surfaces to form a diffusion aluminide coating.
    Type: Grant
    Filed: September 30, 2009
    Date of Patent: November 27, 2012
    Assignee: General Electric Company
    Inventors: Dennis William Cavanaugh, Vinod P. Pareek, Nuo Sheng, Surinder Pabla, Daniel J. Dorriety
  • Publication number: 20120247621
    Abstract: A casting process for producing metal alloy castings, facecoats and apparatuses suitable for carrying out the process, and castings produced by the process. The casting process entails the use of a mold having a cavity with a continuous aluminum-containing solid facecoat on its surface. A molten quantity of a metal alloy is introduced into the mold cavity so that the molten alloy contacts the solid facecoat. The mold is then allowed to cool to solidify the molten alloy and form a cast product. During the casting process, aluminum in the solid facecoat diffuses into the cast product to form an aluminum-containing surface region at the casting surface. Following removal of the cast product from the mold, an alumina-containing scale grows on the casting surface as a result of oxidation of the casting surface region.
    Type: Application
    Filed: March 29, 2011
    Publication date: October 4, 2012
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: George Albert Goller, Dennis William Cavanaugh
  • Patent number: 8262812
    Abstract: In one embodiment, a method for forming an article with a diffusion portion comprises: forming a slurry comprising chromium and silicon, applying the slurry to the article, and heating the article to a sufficient temperature and for a sufficient period of time to diffuse chromium and silicon into the article and form a diffusion portion comprising silicon and a microstructure comprising ?-chromium. In one embodiment, a gas turbine component comprises: a superalloy and a diffusion portion having a depth of less than or equal to 60 ?m measured from the superalloy surface into the gas turbine component. The diffusion portion has a diffusion surface having a microstructure comprising greater than or equal to 40% by volume ?-chromium.
    Type: Grant
    Filed: April 4, 2007
    Date of Patent: September 11, 2012
    Assignee: General Electric Company
    Inventors: David Andrew Helmick, Dennis William Cavanaugh, Ganjiang Feng, David Vincent Bucci
  • Publication number: 20120156054
    Abstract: A process for creating a near-surface cooling passage in an air-cooled turbomachine component. The process entails forming a channel in a surface of a surface region of the component so that the channel is open at the surface and fluidically connected to a first cooling passages within the component. A metallic layer is then deposited on the surface and over the channel without filling the channel. The metallic layer closes the channel at the surface of the surface region to define therewith a second cooling passage within the component that is fluidically connected to the first cooling passages. A coating system is then deposited on the metallic layer to define an outermost surface of the component. The second cooling passage is closer to the outermost surface of the component than the first cooling passages.
    Type: Application
    Filed: December 15, 2010
    Publication date: June 21, 2012
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Benjamin Paul Lacy, David Vincent Bucci, Srikanth Chandrudu Kottilingam, Dennis William Cavanaugh
  • Publication number: 20110318601
    Abstract: In one embodiment, a method for forming an article with a diffusion portion comprises: forming a slurry comprising chromium and silicon, applying the slurry to the article, and heating the article to a sufficient temperature and for a sufficient period of time to diffuse chromium and silicon into the article and form a diffusion portion comprising silicon and a microstructure comprising ?-chromium. In one embodiment, a gas turbine component comprises: a superalloy and a diffusion portion having a depth of less than or equal to 60 ?m measured from the superalloy surface into the gas turbine component. The diffusion portion has a diffusion surface having a microstructure comprising greater than or equal to 40% by volume ?-chromium.
    Type: Application
    Filed: September 6, 2011
    Publication date: December 29, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: David Andrew Helmick, Dennis William Cavanaugh, Ganjiang Feng, David Vincent Bucci
  • Publication number: 20110300404
    Abstract: An oxidation resistant component with high temperature strength and a method of creating such component are disclosed. A modified base metal may be formed by adding at least two strengthening additives to a base metal, the base metal being substantially free from both nickel and cobalt and comprising from about 1% to about 27% chromium by weight. The modified base metal may then be formed into a component and an aluminum-containing slurry may be applied to a surface of the component. The component may then be heated to diffuse aluminum into the component and to form an aluminum diffusion surface layer therein.
    Type: Application
    Filed: June 3, 2010
    Publication date: December 8, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: George Albert Goller, Dennis William Cavanaugh
  • Publication number: 20110300454
    Abstract: An oxidation resistant fuel cell component and a method for creating an aluminum diffusion surface layer within a fuel cell component to reduce chromium contamination occurring during operation of a fuel cell are disclosed. Generally, an aluminum-containing slurry may be applied to the fuel cell component. The component may then be heated to diffuse aluminum into the component and to form an aluminum diffusion surface layer therein. The surface layer may be characterized by an intermetallic aluminum-containing phase extending below the surface of the fuel cell component.
    Type: Application
    Filed: June 3, 2010
    Publication date: December 8, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: George Albert Goller, Dennis William Cavanaugh