Patents by Inventor James Anthony Ruud

James Anthony Ruud 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: 20200024718
    Abstract: The present application provides Calcia-Magnesia-Alumina-Silica (CMAS) (or molten silicate) resistant thermal barrier coatings (IBC). The coatings include elongate growth domains of non-equiaxed, randomly arranged overlapping grains or splats. The elongate growth domains include overlapping individual, randomly distributed splats of tough and soft phases. In some embodiments, the elongate growth domains are formed via air plasma spray. In some embodiments, the tough phases are at least partially stabilized zirconia and/or hafnia compositions, and the soft phases are CMAS (or molten silicate) reactive or resistant compositions. Within each elongate growth domain, the mixture of the tough and soft phases act together to limit penetration of CMAS and also provide sufficient domain toughness to minimize cracking forces produced during crystallization of infiltrated CMAS.
    Type: Application
    Filed: December 13, 2018
    Publication date: January 23, 2020
    Inventors: Larry Steven Rosenzweig, James Anthony Ruud, Shankar Sivaramakrishnan
  • Patent number: 10370292
    Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process. The method may also include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg, such as a prepreg tape. The ceramic fibers may be substantially SiC fibers, for example.
    Type: Grant
    Filed: October 5, 2017
    Date of Patent: August 6, 2019
    Assignee: General Electric Company
    Inventors: Daniel Gene Dunn, James Anthony Ruud, Pierre-Andre Bui, Gregory Scot Corman, James Scott Vartuli
  • Publication number: 20190210932
    Abstract: A ceramic fiber processing apparatus and method for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs) is provided. The apparatus includes a frame including a plurality of unidirectional ceramic fibers wound thereabout and extending across a void therein the frame to define a first planar array of ceramic fibers and a second planar array of ceramic fibers. During use, the frame is disposed in the ceramic fiber processing apparatus in a manner to enable gripping of the first planar array of ceramic fibers with a first gripper assembly and gripping of the second planar array of ceramic fibers with a second gripper assembly. A cutting mechanism provides cutting of the plurality of unidirectional ceramic fibers to separate the first planar array of ceramic fibers and the second planar array of ceramic fibers from one another.
    Type: Application
    Filed: January 10, 2018
    Publication date: July 11, 2019
    Inventors: Danilo Veljkovic, Robert Hanet, James Anthony Ruud, Thomas Joseph Post
  • Publication number: 20190106779
    Abstract: A system and method described herein relate to applying an overlay metal-based coating to a metal-based substrate. An article is provided, which includes a metal-based substrate having an overlay metal-based coating disposed on the substrate at an interface. The interface is configured such that a crack formed within the overlay metal-based coating and approaching the interface has a propagation path that is more energetically favorable along the interface than through the interface and into the metal-based substrate.
    Type: Application
    Filed: October 10, 2017
    Publication date: April 11, 2019
    Inventors: Andrew Joseph Detor, Richard DiDomizio, James Anthony Ruud, Soumya Nag
  • Patent number: 10179945
    Abstract: The present application provides Calcia-Magnesia-Alumina-Silica (CMAS) (or molten silicate) resistant thermal barrier coatings (TBC). The coatings include elongate growth domains of non-equiaxed, randomly arranged overlapping grains or splats. The elongate growth domains include overlapping individual, randomly distributed splats of tough and soft phases. In some embodiments, the elongate growth domains are formed via air plasma spray. In some embodiments, the tough phases are at least partially stabilized zirconia and/or hafnia compositions, and the soft phases are CMAS (or molten silicate) reactive or resistant compositions. Within each elongate growth domain, the mixture of the tough and soft phases act together to limit penetration of CMAS and also provide sufficient domain toughness to minimize cracking forces produced during crystallization of infiltrated CMAS.
    Type: Grant
    Filed: December 16, 2013
    Date of Patent: January 15, 2019
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Larry Steven Rosenzweig, James Anthony Ruud, Shankar Sivaramakrishnan
  • Publication number: 20180245194
    Abstract: An article includes a substrate comprising a precipitate-strengthened alloy and a coating disposed over the substrate. The alloy comprises a) a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers; or b) a population of gamma-double-prime precipitates having a median size less than about 300 nanometers. The coating comprises at least two elements, and further comprises a plurality of prior particles. At least a portion of the coating is substantially free of rapid solidification artifacts. Methods for fabricating the article and for processing powder useful for fabricating the article are also provided.
    Type: Application
    Filed: April 27, 2018
    Publication date: August 30, 2018
    Inventors: Andrew Joseph Detor, Leonardo Ajdelsztajn, Thomas Michael Bigelow, Richard Didomizio, Andrew William Emge, James Anthony Ruud, Michael James Weimer
  • Patent number: 10052789
    Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include at least one of depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process and impregnating the ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg. In some embodiments, the ceramic fibers of the planar array may include a coating, and the method may include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg.
    Type: Grant
    Filed: November 25, 2015
    Date of Patent: August 21, 2018
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Daniel Gene Dunn, James Anthony Ruud, Pierre-Andre Bui, Gregory Scot Corman, James Scott Vartuli
  • Patent number: 10017844
    Abstract: An article includes a substrate comprising a precipitate-strengthened alloy and a coating disposed over the substrate. The alloy comprises a) a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers; or b) a population of gamma-double-prime precipitates having a median size less than about 300 nanometers. The coating comprises at least two elements, and further comprises a plurality of prior particles. At least a portion of the coating is substantially free of rapid solidification artifacts. Methods for fabricating the article and for processing powder useful for fabricating the article are also provided.
    Type: Grant
    Filed: December 18, 2015
    Date of Patent: July 10, 2018
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Andrew Joseph Detor, Leonardo Ajdelsztajn, Thomas Michael Bigelow, Richard Didomizio, Andrew William Emge, James Anthony Ruud, Michael James Weimer
  • Patent number: 9931815
    Abstract: 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: Grant
    Filed: March 12, 2014
    Date of Patent: April 3, 2018
    Assignee: General Electric Company
    Inventors: David Paul Mourer, Leonardo Ajdelsztajn, Kenneth Rees Bain, Andrew Joseph Detor, Andrew William Emge, James Anthony Ruud, Michael James Weimer
  • Publication number: 20180029928
    Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process. The method may also include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg, such as a prepreg tape. The ceramic fibers may be substantially SiC fibers, for example.
    Type: Application
    Filed: October 5, 2017
    Publication date: February 1, 2018
    Inventors: Daniel Gene DUNN, James Anthony RUUD, Pierre-Andre BUI, Gregory Scot CORMAN, James Scott VARTULI
  • Patent number: 9816392
    Abstract: A method for fabricating thermal barrier coatings. The thermal barrier coatings are produced with a fine grain size by reverse co-precipitation of fine powders. The powders are then sprayed by a solution plasma spray that partially melts the fine powders while producing a fine grain size with dense vertical cracking. The coatings comprise at least one of 45%-65% Yb2O3 the balance zirconia (zirconium oxide), Yb/Y/Hf/Ta the balance zirconia (zirconium oxide) and 2.3-7.8% La, 1.4-5.1% Y and the balance zirconia (zirconium oxide) and are characterized by a thermal conductivity that is about 25-50% lower than that of thermal barrier coatings comprising YSZ. The thermal barrier coatings also are characterized by at least one of excellent erosion resistance, fracture toughness and abrasion resistance.
    Type: Grant
    Filed: April 10, 2013
    Date of Patent: November 14, 2017
    Assignee: General Electric Company
    Inventors: Padmaja Parakala, Surinder Singh Pabla, Joshua Lee Margolies, James Anthony Ruud, Krishnamurthy Anand, Jon Conrad Schaeffer
  • Patent number: 9815736
    Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process. The method may also include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg, such as a prepreg tape. The ceramic fibers may be substantially SiC fibers, for example.
    Type: Grant
    Filed: November 25, 2015
    Date of Patent: November 14, 2017
    Assignee: General Electric Company
    Inventors: Daniel Gene Dunn, James Anthony Ruud, Pierre-Andre Bui, Gregory Scot Corman, James Scott Vartuli
  • Publication number: 20170175244
    Abstract: An article includes a substrate comprising a precipitate-strengthened alloy and a coating disposed over the substrate. The alloy comprises a) a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers; or b) a population of gamma-double-prime precipitates having a median size less than about 300 nanometers. The coating comprises at least two elements, and further comprises a plurality of prior particles. At least a portion of the coating is substantially free of rapid solidification artifacts. Methods for fabricating the article and for processing powder useful for fabricating the article are also provided.
    Type: Application
    Filed: December 18, 2015
    Publication date: June 22, 2017
    Inventors: Andrew Joseph Detor, Leonardo Ajdelsztajn, Thomas Michael Bigelow, Richard Didomizio, Andrew William Emge, James Anthony Ruud, Michael James Weimer
  • Publication number: 20170144925
    Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process. The method may also include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg, such as a prepreg tape. The ceramic fibers may be substantially SiC fibers, for example.
    Type: Application
    Filed: November 25, 2015
    Publication date: May 25, 2017
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Daniel Gene DUNN, James Anthony RUUD, Pierre-Andre BUI, Gregory Scot CORMAN, James Scott VARTULI
  • Publication number: 20170144329
    Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include at least one of depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process and impregnating the ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg. In some embodiments, the ceramic fibers of the planar array may include a coating, and the method may include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg.
    Type: Application
    Filed: November 25, 2015
    Publication date: May 25, 2017
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Daniel Gene DUNN, James Anthony RUUD, Pierre-Andre BUI, Gregory Scot CORMAN, James Scott VARTULI
  • Publication number: 20170101875
    Abstract: A method for coating a surface of a substrate is provided. The method includes providing a suspension or a precursor comprising feedstock material suspended in a liquid medium. Further, the method includes spraying the suspension or the precursor onto the surface at a spray angle less than about 75 degrees to a tangent of the surface.
    Type: Application
    Filed: December 20, 2016
    Publication date: April 13, 2017
    Inventors: Larry Steven Rosenzweig, James Anthony Ruud, Shankar Sivaramakrishnan
  • Patent number: 9611391
    Abstract: One aspect of the present invention includes an article. The article includes a substrate and a coating disposed on the substrate, wherein the coating includes a plurality of cermet particles bonded along their prior particle boundaries. The plurality of cermet particles have a median particle size less than about 5 microns and less than 25 percent of the plurality of cermet particles include melted and re-solidified particles. Gate valves are also presented.
    Type: Grant
    Filed: March 3, 2014
    Date of Patent: April 4, 2017
    Assignee: General Electric Company
    Inventors: Leonardo Ajdelsztajn, James Anthony Ruud, Dennis Michael Gray
  • Patent number: 9556505
    Abstract: A coating comprising a first surface and a second surface is provided. The coating includes a plurality of growth domains. An orientation of at least one growth domain of the plurality of growth domains is non-vertical with respect to the first surface of the coating. One or more growth domains of the plurality of growth domains comprise a plurality of at least partially melted and solidified particles.
    Type: Grant
    Filed: August 31, 2012
    Date of Patent: January 31, 2017
    Assignee: General Electric Company
    Inventors: Larry Steven Rosenzweig, James Anthony Ruud, Shankar Sivaramakrishnan
  • Patent number: 9334806
    Abstract: A method for manufacturing a fuel contacting component that facilitates reducing coke formation on at least one surface of the fuel contacting component is disclosed herein. The method includes applying a slurry composition including a powder including aluminum to the component surface, wherein the fuel contacting component is formed by an additive manufacturing process. The slurry composition is heat treated to diffuse the aluminum into the component surface. The heat treatment comprises forming a diffusion aluminide coating on the component surface, wherein the diffusion coating comprises a diffusion sublayer formed on the component surface and an additive sublayer formed on the diffusion sublayer. The method further comprises removing the additive sublayer of the diffusion aluminide coating with at least one aqueous solution such that the diffusion sublayer and the component surface are substantially unaffected, wherein the diffusion layer facilitates preventing coke formation on component surface.
    Type: Grant
    Filed: September 5, 2013
    Date of Patent: May 10, 2016
    Assignee: General Electric Company
    Inventors: William Thomas Carter, James Anthony Ruud, Jr., Lawrence Bernard Kool, Justin John Gambone, Jr., Christine Mary Furstoss
  • Patent number: 9328918
    Abstract: Different types of apparatus for fabricating a deposit, method of deposition and an article are presented. The apparatus include a thermal spray gun comprising a combustion chamber, combustion zone, an air injection port, a fuel injection port, a nozzle and a liquid injection port. The combustion zone exists between the inlet side and outlet side of the combustion chamber. The method includes, among other things, providing a fuel and an oxidizer inside the combustion zone, initiating combustion inside the combustion zone, and directing products of the combustion toward the outlet side to create a combustion product stream. The method also includes introducing a feedstock mixture comprising a feedstock material and a liquid into the combustion product stream to create an entrained feedstock stream, and expelling the entrained feedstock stream from the spray gun through a nozzle to form a deposit on a surface of the article.
    Type: Grant
    Filed: May 28, 2010
    Date of Patent: May 3, 2016
    Assignee: General Electric Company
    Inventors: Leonardo Ajdelsztajn, James Anthony Ruud