Patents by Inventor Jon Schaeffer
Jon Schaeffer 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: 10077494Abstract: A process for forming a diffusion coating on a substrate is disclosed, including preparing a slurry including a donor metal powder, an activator powder, and a binder, and applying the slurry to the substrate. The slurry is dried on the substrate, forming a slurry layer on the substrate. A covering composition is applied over the slurry layer, and the covering composition is dried, forming at least one covering layer enclosing the slurry layer against the substrate. The slurry layer and the at least one covering layer are heated to form the diffusion coating on the substrate, the diffusion coating including an additive layer and an interdiffusion zone disposed between the substrate and the additive layer.Type: GrantFiled: September 13, 2016Date of Patent: September 18, 2018Assignee: General Electric CompanyInventors: Dechao Lin, David Vincent Bucci, Shan Liu, Jon Schaeffer, John Adams, Ron Hendrix
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Publication number: 20180073123Abstract: A process for forming a diffusion coating on a substrate is disclosed, including preparing a slurry including a donor metal powder, an activator powder, and a binder, and applying the slurry to the substrate. The slurry is dried on the substrate, forming a slurry layer on the substrate. A covering composition is applied over the slurry layer, and the covering composition is dried, forming at least one covering layer enclosing the slurry layer against the substrate. The slurry layer and the at least one covering layer are heated to form the diffusion coating on the substrate, the diffusion coating including an additive layer and an interdiffusion zone disposed between the substrate and the additive layer.Type: ApplicationFiled: September 13, 2016Publication date: March 15, 2018Inventors: Dechao LIN, David Vincent BUCCI, Shan LIU, Jon SCHAEFFER, John ADAMS, Ron HENDRIX
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Publication number: 20070241169Abstract: A method of welding superalloy components comprising: (a) forming a weld prep groove at an interface of the components; (b) welding the components using a filler material at ambient temperature; (c) covering the filler material and adjacent surfaces of the components with a braze paste; and (d) heat treating the components, the heat treatment including a stress-relief cycle and a braze cycle. A similar process may be used to repair a crack in a nickel-based superalloy component.Type: ApplicationFiled: April 13, 2006Publication date: October 18, 2007Applicant: General Electric CompanyInventors: Michael Arnett, Daniel Nowak, Jon Schaeffer
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Publication number: 20070082221Abstract: A nickel-base superalloy substrate includes a surface region having an integrated aluminum content of from about 18 to about 24 percent by weight and an integrated platinum content of from about 18 to about 45 percent by weight, with the balance components of the substrate. The substrate is preferably a single-crystal advanced superalloy selected for use at high temperatures. The substrate may optionally have a ceramic layer deposited over the platinum-aluminide region, to produce a thermal barrier coating system. The platinum-aluminide region is produced by diffusing platinum into the substrate surface, and thereafter diffusing aluminum into the substrate surface.Type: ApplicationFiled: January 17, 2006Publication date: April 12, 2007Applicant: General Electric CompanyInventor: Jon Schaeffer
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Publication number: 20070071905Abstract: A method of coating a substrate comprising (a) applying a first coating to the substrate; (b) roughening an outer surface of the first coating using a high pressure water jet; and (c) applying a second coating over the first coating.Type: ApplicationFiled: September 29, 2005Publication date: March 29, 2007Applicant: General Electric CompanyInventors: Jon Schaeffer, David Bucci
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Publication number: 20070048450Abstract: A nickel-base superalloy substrate includes a surface region having an integrated aluminum content of from about 18 to about 24 percent by weight and an integrated platinum content of from about 18 to about 45 percent by weight, with the balance components of the substrate. The substrate is preferably a single-crystal advanced superalloy selected for use at high temperatures. The substrate may optionally have a ceramic layer deposited over the platinum-aluminide region, to produce a thermal barrier coating system. The platinum-aluminide region is produced by diffusing platinum into the substrate surface, and thereafter diffusing aluminum into the substrate surface.Type: ApplicationFiled: January 5, 2006Publication date: March 1, 2007Applicant: General Electric CompanyInventor: Jon Schaeffer
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Publication number: 20070048538Abstract: A nickel-base superalloy substrate includes a surface region having an integrated aluminum content of from about 18 to about 24 percent by weight and an integrated platinum content of from about 18 to about 45 percent by weight, with the balance components of the substrate. The substrate is preferably a single-crystal advanced superalloy selected for use at high temperatures. The substrate may optionally have a ceramic layer deposited over the platinum-aluminide region, to produce a thermal barrier coating system. The platinum-aluminide region is produced by diffusing platinum into the substrate surface, and thereafter diffusing aluminum into the substrate surface.Type: ApplicationFiled: January 17, 2006Publication date: March 1, 2007Applicant: General Electric CompanyInventor: Jon Schaeffer
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Publication number: 20070044872Abstract: An Fe—Ni—Cr alloy formulated to contain a strengthening phase that is able to maintain a fine grain structure during forging and high temperature processing of the alloy. The alloy contains a sufficient amount of titanium, zirconium, carbon and nitrogen so that fine titanium and zirconium carbonitride precipitates formed thereby are near their solubility limit in the alloy when molten. In the production of an article from such an alloy by thermomechanical processing, a dispersion of the fine titanium and zirconium carbonitride precipitates form during solidification of the melt and remain present during subsequent elevated processing steps to prohibit austenitic grain growth.Type: ApplicationFiled: February 28, 2006Publication date: March 1, 2007Applicant: GENERAL ELECTRIC COMPANYInventors: Jianqiang Chen, Jon Schaeffer, Anjilivelil Kuruvilla
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Publication number: 20070020135Abstract: A process for producing turbine rotors and other large rotating components of power-generating gas turbine engines using powder metallurgy techniques. The process involves forming a powder of a gamma prime or gamma double prime precipitation-strengthened nickel-based superalloy whose particles are about 0.100 mm in diameter or smaller. The powder is placed in a can and consolidated to produce an essentially fully dense consolidation, which is then hot worked to produce a billet of a size sufficient to form a forging of at least 2300 kg. The billet is forged at a temperature and strain rate to produce a forging with a uniform fine grain of ASTM 10 or finer. Thereafter, the forging may undergo a heat treatment to achieve a desired balance of mechanical properties while retaining a uniform grain size of ASTM 10 or finer.Type: ApplicationFiled: July 22, 2005Publication date: January 25, 2007Applicant: GENERAL ELECTRIC COMPANYInventors: Joseph Jackson, Jon Schaeffer
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Publication number: 20060131366Abstract: A weld process cuitable for repairing precipitation-strengthened superalloys, and particularly gamma prime-strengthened nickel-based superalloys. The process entails forming a weldment in a cavity present in a surface of an article formed of a precipitation-strengthened superalloy. The cavity has a root region and a cap region between the root region and the surface of the article. A solid body formed of a superalloy composition is placed in the root region of the cavity so as to occupy a first portion but not a second portion of the root region. A first filler material formed of a solid solution-strengthened superalloy is then weld-deposited in the second portion of the root region. Subsequently, a second filler material formed of a precipitation-strengthened superalloy is weld-deposited in the cap region of the cavity.Type: ApplicationFiled: December 22, 2004Publication date: June 22, 2006Applicant: GENERAL ELECTRIC COMPANYInventors: Jon Schaeffer, Ariel Jacala, Doyle Lewis, Thaddeus Strusinski, Frederick Dantzler, Eugene Clemens, Paul Wilson, Michael Butler, Jeffrey Killough
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Publication number: 20050260434Abstract: A bi-layer bond coating for use on metal alloy components exposed to hostile thermal and chemical environment, such as a gas turbine engine used to generate electricity and the method for applying such coatings. The preferred coatings include a bi-layer bond coat applied to the metal substrate, with both layers being applied using high velocity oxy-fuel (HVOF) thermal spraying. In one embodiment, bond coatings in accordance with the invention can be used in combination with a thermal barrier coating (“TBC”). However, the invention can also take other forms, such as a stand alone overlay coating. Bi-layer bond coatings in accordance with the invention consist of a dense first inner layer (such as iron, nickel or cobalt-based alloys) that provides oxidation protection to the metal substrate, and a second outer layer having controlled porosity that tends to promote roughness, mechanical compliance, and promotes adherence of the TBC.Type: ApplicationFiled: May 18, 2004Publication date: November 24, 2005Applicant: General Electric CompanyInventors: Warren Nelson, Jon Schaeffer, Sharon Swede, David Bucci, Joseph Debarro, Terry Strout, Tyrone Mortensen
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Publication number: 20050121116Abstract: A coated article is prepared by furnishing a nickel-base article substrate having a free sulfur content of more than 0 but less than about 1 part per million by weight. A protective layer is formed at a surface of the article substrate. The protective layer includes a platinum aluminide diffusion coating. The protective layer may be substantially yttrium-free, or have a controlled amount of yttrium. A ceramic layer may overlie the protective layer.Type: ApplicationFiled: September 17, 2004Publication date: June 9, 2005Applicant: GENERAL ELECTRIC COMPANYInventors: William Walston, Jon Schaeffer, Wendy Murphy
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Publication number: 20050019160Abstract: Third stage turbine buckets have airfoil profiles substantially in accordance with Cartesian coordinate values of X, Y and Z set forth Table I wherein X and Y values are in inches and the Z values are non-dimensional values from 0 to 0.938 convertible to Z distances in inches by multiplying the Z values by the height of the airfoil in inches. The X and Y values are distances which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z. The profile sections at each distance Z are joined smoothly to one another to form a complete airfoil shape. The X and Y distances may be scalable as a function of the same constant or number to provide a scaled up or scaled down airfoil section for the bucket. The nominal airfoil given by the X, Y and Z distances lies within an envelop of ±0.150 inches in directions normal to the surface of the airfoil.Type: ApplicationFiled: July 23, 2003Publication date: January 27, 2005Inventors: Susan Hyde, Robert By, Judd Tressler, Jon Schaeffer, Calvin Sims
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Publication number: 20050013695Abstract: Fourth stage turbine buckets have airfoil profiles substantially in accordance with Cartesian coordinate values of X, Y and Z set forth Table I wherein X and Y values are in inches and the Z values are non-dimensional values from 0 to 1 convertible to Z distances in inches by multiplying the Z values by the height of the airfoil in inches. The X and Y values are distances which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z. The profile sections at each distance Z are joined smoothly to one another to form a complete airfoil shape. The X and Y distances may be scalable as a function of the same constant or number to provide a scaled up or scaled down airfoil section for the bucket. The nominal airfoil given by the X, Y and Z distances lies within an envelop of ±0.150 inches in directions normal to the surface of the airfoil.Type: ApplicationFiled: July 18, 2003Publication date: January 20, 2005Inventors: Susan Hyde, Robert By, Jon Schaeffer, Calvin Sims, Michael Boisclair