Patents by Inventor Joshua Lee Margolies

Joshua Lee Margolies 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: 20190169730
    Abstract: A method for controlling the porosity parameter of porous thermal barrier coatings is presented. The method includes disposing a feedstock material on a substrate to form a porous thermal barrier coating. The feedstock material includes a gas-forming additive and a thermal barrier coating material. The disposing step further includes controlling the porosity parameter of the porous thermal barrier coating by controlling a feedstock material feed rate, an amount of the gas-forming additive in the feedstock material, a temperature of the disposed feedstock material on the substrate, or combinations thereof.
    Type: Application
    Filed: December 4, 2017
    Publication date: June 6, 2019
    Inventors: Theodore Robert Grossman, Joshua Lee Margolies
  • Publication number: 20180363478
    Abstract: A method for forming a coated turbine component and a coated turbine component is provided. The method includes a step of providing a component having a substrate comprising a trailing edge face. The method further includes a step of applying a thermal barrier coating or environmental barrier coating selectively to the substrate to form a discontinuous transition from a hot gas path surface at the trailing edge face to discourage hot gas flow along the trailing edge face.
    Type: Application
    Filed: June 15, 2017
    Publication date: December 20, 2018
    Inventors: Joshua Lee MARGOLIES, Victor John MORGAN, Matthew Troy HAFNER
  • Publication number: 20180363477
    Abstract: A coated ceramic matrix composite or metallic component and a gas turbine assembly is provided. The component comprises a substrate comprising a first surface and a hot gas path surface. The hot gas path surface is arranged and disposed to contact a hot gas flow when the component is installed in the gas turbine. The first surface is disposed at an angle to the hot gas path surface and opposes at least one adjacent component when the component is installed in the gas turbine. The component further comprises an angled or rounded feature extending from the first surface to the hot gas path surface. The component further comprises an environmental barrier coating or thermal barrier coating on at least a portion of the hot gas path surface. The angled or rounded feature reduces an incidence angle of the hot gas flow onto the first surface. The gas turbine assembly comprises a plurality of the coated components.
    Type: Application
    Filed: June 15, 2017
    Publication date: December 20, 2018
    Inventors: Matthew Troy HAFNER, Joshua Lee MARGOLIES
  • Publication number: 20180363476
    Abstract: A coated ceramic matrix composite component and a gas turbine assembly are provided. The coated ceramic matrix composite component comprises a substrate comprising an endface surface and a hot gas path surface. The hot gas path surface is arranged and disposed to contact a hot gas path when the component is installed in the gas turbine assembly. The endface surface is disposed at an endface angle to the hot gas path surface and opposing at least one adjacent component when the component is installed in the gas turbine assembly. The coated ceramic matrix composite component further comprises an environmental barrier coating on at least a portion of the endface surface.
    Type: Application
    Filed: June 15, 2017
    Publication date: December 20, 2018
    Inventors: Matthew Troy HAFNER, Joshua Lee MARGOLIES
  • Patent number: 9995169
    Abstract: A process of forming a calcium-magnesium-aluminosilicate (CMAS) penetration resistant coating, and a CMAS penetration resistant coating are disclosed. The process includes providing a thermal barrier coating having a dopant, and exposing the thermal barrier coating to calcium-magnesium-aluminosilicate and gas turbine operating conditions. The exposing forming a calcium-magnesium-aluminosilicate penetration resistant layer. The coating includes a thermal barrier coating composition comprising a dopant selected from the group consisting of rare earth elements, non-rare earth element solutes, and combinations thereof. Additional or alternatively, the coating includes a thermal barrier coating and an impermeable barrier layer or a washable sacrificial layer positioned on an outer surface of the thermal barrier coating.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: June 12, 2018
    Assignee: General Electric Company
    Inventors: Jon Conrad Schaeffer, Surinder Singh Pabla, Paul Stephen Dimascio, Krishnamurthy Anand, Joshua Lee Margolies, Padmaja Parakala
  • Publication number: 20180106154
    Abstract: A method of forming an article includes forming a plurality of channels and ridges in a silicon-containing layer on a surface of a substrate of the article using a mask placed on the surface of the substrate or the silicon-containing layer.
    Type: Application
    Filed: October 13, 2016
    Publication date: April 19, 2018
    Inventors: Donald Joseph BALDWIN, Joshua Lee MARGOLIES, Jacob John Kittleson
  • Publication number: 20170342910
    Abstract: The present disclosure is directed to a system for attaching an instrument lead to a gas turbine engine component. The system includes a gas turbine engine component that includes a surface. A first sleeve couples to the surface of the gas turbine engine component. The first sleeve defines a first sleeve passageway extending therethrough. An instrument lead extends through the first sleeve passageway. A first potting material couples the instrument lead to the first sleeve to prevent the instrument lead from moving longitudinally relative to the first sleeve.
    Type: Application
    Filed: May 25, 2016
    Publication date: November 30, 2017
    Inventors: Zachary John Snider, Joshua Lee Margolies, Kurt Kramer Schleif
  • 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
  • Publication number: 20170191152
    Abstract: Methods of making an environmental barrier coating (EBC) for a substrate are provided that include providing an EBC feedstock comprising a rare earth element composition, in which a portion of the composition produces a volatile species during an air plasma spray coating process, providing a first additive that comprises or produces the volatile species during the air plasma spray coating process, injecting the EBC feedstock into a plasma spray plume during the air plasma spray coating process; and injecting the first additive into at least one of the plasma spray plume and a plasma torch nozzle during the air plasma spray coating process, in which the EBC has a composition that is substantially similar to the composition of the EBC feedstock. Also provided are processes for air plasma spray coating an EBC onto a substrate.
    Type: Application
    Filed: December 31, 2015
    Publication date: July 6, 2017
    Inventors: Theodore Robert Grossman, Joshua Lee Margolies
  • Patent number: 9597746
    Abstract: A composite wire for use with a wire arc spray system and related methods. The composite wire can include: a low melting point material at a core region thereof and a cladding including a metal surrounding the core region, the low metal point material having a melting point less than that of the metal, wherein the low melting point material includes a polymer in the form of a powder having particles having a size of from approximately 1 nanometer to approximately 100 nanometers.
    Type: Grant
    Filed: July 2, 2014
    Date of Patent: March 21, 2017
    Assignee: General Electric Company
    Inventors: Joshua Lee Margolies, Surinder Singh Pabla
  • Patent number: 9527109
    Abstract: A coating process and coated article are disclosed. The coating process includes positioning an article relative to an inductor, heating the article with the inductor, then applying a coating material over the article to form a crystalline coating. The heating of the article increases a first temperature of a surface of the article to a second temperature favoring crystal formation. Another coating process includes positioning an article, uniformly heating a surface of the article to a second temperature favoring crystal formation, then applying an environmental barrier coating material over the surface of the article to form a crystalline environmental barrier coating. The application of the environmental barrier coating is performed through air plasma spray deposition. The coated article includes an article having a complex geometry, and a crystalline coating applied on a surface of the article. The crystalline coating includes increased resistant to delamination.
    Type: Grant
    Filed: June 5, 2013
    Date of Patent: December 27, 2016
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Joshua Lee Margolies, Theodore Robert Grossman
  • Publication number: 20160340768
    Abstract: A bond layer may be applied to the substrate of an article and a first layer may be applied to the bond layer by thermal spray. A second layer may be applied above the first layer by slurry coating.
    Type: Application
    Filed: February 23, 2016
    Publication date: November 24, 2016
    Inventors: Joshua Lee Margolies, Herbert Chidsey Roberts, III, Don Mark Lipkin, Glen Harold Kirby, Nicholas Edward Antolino
  • Patent number: 9347126
    Abstract: A process of fabricating a thermal barrier coating is disclosed. The process includes cold spraying a substrate with a feedstock to form a thermal barrier coating and concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating. The cold spraying is in a region having an oxygen concentration of at least 10%. In another embodiment, the process includes heating a feedstock with a laser and cold spraying a substrate with the feedstock to form a thermal barrier coating. At least a portion of the feedstock is retained in the thermal barrier coating. In another embodiment, the process of fabricating a thermal barrier coating includes heating a substrate with a laser and cold spraying the substrate with a feedstock to form a thermal barrier coating.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: May 24, 2016
    Assignee: General Electric Company
    Inventors: Surinder Singh Pabla, Joshua Lee Margolies, Eklavya Calla, Padmaja Parakala
  • Patent number: 9315888
    Abstract: Various aspects of the present disclosure relate to a nozzle insert which may be used with a thermal spray gun apparatus. A nozzle insert according to the disclosure may include a body having an outer surface, the outer surface of the body being configured to circumferentially contact and transfer heat to an inner face of a thermal spray gun nozzle of a thermal spray gun. The body of the nozzle insert may be removed from the thermal spray gun nozzle without disassembling the thermal spray gun, and includes an axial passage configured to communicate a plasma discharge from the nozzle insert. A thermal spray gun apparatus and a thermal spray gun system including the nozzle insert are also disclosed.
    Type: Grant
    Filed: December 2, 2013
    Date of Patent: April 19, 2016
    Assignee: General Electric Company
    Inventors: Donald Joseph Baldwin, Joseph Garfield Albanese, Joshua Lee Margolies
  • Publication number: 20150354393
    Abstract: Methods of manufacturing turbine shrouds with an abradable coating that balance the apparently contradictory requirements of high flowpath solidity, low blade tip wear, and good durability in service. The methods include obtaining a shroud substrate. The methods may include obtaining a coating system on the shroud substrate. The methods include forming an abradable coating on a surface of the coating system so as to form a substantially smooth flowpath surface. Forming the abradable coating includes forming a relatively dense scaffold and relatively porous filler regions in-between the relatively dense abradable scaffold. The methods may also include machining the abradable so as to achieve a substantially smooth flowpath surface comprising a relatively porous abradable phase surrounded by a relatively dense, high-durability corrale phase.
    Type: Application
    Filed: June 10, 2014
    Publication date: December 10, 2015
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Don Mark LIPKIN, Luc Stephane LEBLANC, Joshua Lee MARGOLIES, Nicholas Edward ANTOLINO
  • Patent number: 9139477
    Abstract: A ceramic powder and method of forming the ceramic powder capable of being used in coatings to allow components to survive in high temperatures environments, such as the hostile thermal environment of a gas turbine engine. The ceramic powder includes powder particles each having an inner core formed of a first material and an outer region formed of a second material. The inner core has a lower thermal conductivity than the outer region, and the outer region is more erosion resistance relative to the inner core.
    Type: Grant
    Filed: February 18, 2013
    Date of Patent: September 22, 2015
    Assignee: General Electric Company
    Inventors: Surinder Singh Pabla, Joshua Lee Margolies, Padmaja Parakala
  • Publication number: 20150152541
    Abstract: Various aspects of the present disclosure relate to a nozzle insert which may be used with a thermal spray gun apparatus. A nozzle insert according to the disclosure may include a body having an outer surface, the outer surface of the body being configured to circumferentially contact and transfer heat to an inner face of a thermal spray gun nozzle of a thermal spray gun. The body of the nozzle insert may be removed from the thermal spray gun nozzle without disassembling the thermal spray gun, and includes an axial passage configured to communicate a plasma discharge from the nozzle insert. A thermal spray gun apparatus and a thermal spray gun system including the nozzle insert are also disclosed.
    Type: Application
    Filed: December 2, 2013
    Publication date: June 4, 2015
    Applicant: General Electric Company
    Inventors: Donald Joseph Baldwin, Joseph Garfield Albanese, Joshua Lee Margolies
  • Publication number: 20150118444
    Abstract: A method of forming an article includes forming a silicon-containing layer on a silicon-containing region of a surface of a substrate of the article; forming a plurality of channels and ridges in the silicon-containing layer; and forming at least one outer layer overlying the surface of the silicon-containing region. The plurality of channels and ridges may be formed by adding silicon-containing material to the silicon-containing layer. The channels and ridges may be formed by subtracting material from the silicon-containing layer. The channels and ridges may be formed by forming channels or grooves in the silicon-containing region of the surface of the substrate prior to formation of the silicon-containing layer.
    Type: Application
    Filed: October 31, 2013
    Publication date: April 30, 2015
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Don Mark Lipkin, Curtis Alan Johnson, Joshua Lee Margolies, Larry Steven Rosenzweig, Julin Wan
  • Publication number: 20140363684
    Abstract: A coating process and coated article are disclosed. The coating process includes positioning an article relative to an inductor, heating the article with the inductor, then applying a coating material over the article to form a crystalline coating. The heating of the article increases a first temperature of a surface of the article to a second temperature favoring crystal formation. Another coating process includes positioning an article, uniformly heating a surface of the article to a second temperature favoring crystal formation, then applying an environmental barrier coating material over the surface of the article to form a crystalline environmental barrier coating. The application of the environmental barrier coating is performed through air plasma spray deposition. The coated article includes an article having a complex geometry, and a crystalline coating applied on a surface of the article. The crystalline coating includes increased resistant to delamination.
    Type: Application
    Filed: June 5, 2013
    Publication date: December 11, 2014
    Inventors: Joshua Lee MARGOLIES, Theodore Robert GROSSMAN
  • Publication number: 20140312006
    Abstract: A composite wire for use with a wire arc spray system and related methods. The composite wire can include: a low melting point material at a core region thereof and a cladding including a metal surrounding the core region, the low metal point material having a melting point less than that of the metal, wherein the low melting point material includes a polymer in the form of a powder having particles having a size of from approximately 1 nanometer to approximately 100 nanometers.
    Type: Application
    Filed: July 2, 2014
    Publication date: October 23, 2014
    Inventors: Joshua Lee Margolies, Surinder Singh Pabla