Patents by Inventor Mark Daniel Gorman

Mark Daniel Gorman 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: 8293324
    Abstract: A coating process and system suitable for use on components subjected to high temperatures. The coating system includes an overlay coating of predominantly B2 phase rhodium aluminide (RhAl) intermetallic compound containing about 25 to about 90 atomic percent rhodium, about 10 to about 60 atomic percent aluminum, optionally up to a combined total of about 25 atomic percent of one or more platinum group metals chosen from the group consisting of platinum, palladium, ruthenium, and iridium, and up to about 20 atomic percent of the base metal and alloying constituents of the substrate. The RhAl intermetallic coating may serve as an environmental coating, a diffusion barrier layer for an overlying environmental coating, or both, with or without an outer ceramic coating.
    Type: Grant
    Filed: April 7, 2008
    Date of Patent: October 23, 2012
    Assignee: General Electric Company
    Inventors: Liang Jiang, Michael Francis Xavier Gigliotti, Jr., Mark Daniel Gorman, Ramgopal Darolia
  • Patent number: 8084094
    Abstract: A coating process for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating process forms a coating system that includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.
    Type: Grant
    Filed: May 14, 2009
    Date of Patent: December 27, 2011
    Assignee: General Electric Company
    Inventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
  • Publication number: 20100266417
    Abstract: A method for applying a NiAl based bond coat and a diffusion aluminide coating to a metal substrate is disclosed. The method comprises providing a superalloy substrate, the superalloy substrate having an external surface; and optionally cleaning the external surface of the superalloy substrate. The method further comprises coating a portion of the external surface of the superalloy substrate, by physical vapor deposition with a layer of a NiAl based metal alloy, wherein the deposited NiAl based metal alloy includes a controlled amount of about 6 to 25 weight percent aluminum and additionally the deposited aluminum level of the NiAl based metal alloy is controlled to be about 50-100% of its final level after aluminizing to form a coated external portion; and subsequently, simultaneously aluminizing the coated external portion and a different surface of the superalloy substrate.
    Type: Application
    Filed: August 7, 2007
    Publication date: October 21, 2010
    Inventors: Mark Daniel Gorman, Brett Allen Boutwell, Robert George Zimmerman, JR.
  • Patent number: 7807231
    Abstract: A process for protecting a thermal barrier coating (TBC) on a component used in a high-temperature environment, such as the hot section of a gas turbine engine. The process applies a protective film on the surface of the TBC to resist infiltration of contaminants such as CMAS that can melt and infiltrate the TBC to cause spallation. The process generally entails applying to the TBC surface a metal composition containing at least one metal whose oxide resists infiltration of CMAS into the TBC. The metal composition is applied so as to form a metal film on the TBC surface and optionally to infiltrate porosity within the TBC beneath its surface. The metal composition is then converted to form an oxide film, with at least a portion of the oxide film forming a surface deposit on the TBC surface.
    Type: Grant
    Filed: November 30, 2005
    Date of Patent: October 5, 2010
    Assignee: General Electric Company
    Inventors: Mark Daniel Gorman, Bangalore Aswatha Nagaraj, Robert Edward Schafrik
  • Publication number: 20090252613
    Abstract: A damaged gas turbine blade which has previously been in service, and which is made of a base metal, is furnished. Any damaged material is removed from the damaged blade tip. The damaged blade tip is weld repaired with a nickel-base superalloy that is more resistant to oxidation resistance than is the base metal in the operating environment of the tip-repaired gas turbine blade. The method does not include any step of coating a lateral surface of the repaired blade tip with a non-ceramic coating after the step of weld repairing.
    Type: Application
    Filed: June 18, 2009
    Publication date: October 8, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Mark Daniel Gorman, Warren Davis Grossklaus, JR.
  • Patent number: 7587818
    Abstract: A damaged gas turbine blade which has previously been in service, and which is made of a base metal, is furnished. Any damaged material is removed from the damaged blade tip. The damaged blade tip is weld repaired with a nickel-base superalloy that is more resistant to oxidation resistance than is the base metal in the operating environment of the tip-repaired gas turbine blade. The method does not include any step of coating a lateral surface of the repaired blade tip with a non-ceramic coating after the step of weld repairing.
    Type: Grant
    Filed: December 23, 2004
    Date of Patent: September 15, 2009
    Assignee: General Electric Company
    Inventors: Mark Daniel Gorman, Warren Davis Grossklaus, Jr.
  • Publication number: 20090220684
    Abstract: A coating process for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating process forms a coating system that includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.
    Type: Application
    Filed: May 14, 2009
    Publication date: September 3, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
  • Patent number: 7581933
    Abstract: A turbine airfoil having an improved impact and erosion resistance. The airfoil comprises: (a) a base segment having an impact resistant leading edge section proximate to the leading edge comprising a material having having a yield strength of least about 250 ksi and an elongation percentage of about 12% or less; and (b) an erosion resistant coating overlaying the base segment at least in the leading and trailing edge portions of the pressure side, the erosion resistant coating comprising at least one ceramic layer having at least one of the following properties: (1) an erosion value of at least about 200 g. of erodent to cause a thickness loss of about 15-20 microns; (2) an erosion volume loss value (V) of about 1.9 or less as defined by the equation V=H?0.18×E0.75×F?1.65 where H is hardness, E is elastic modulus and F is fracture toughness; and (3) an F value of at least about 1.5 MPa*m1/2.
    Type: Grant
    Filed: January 24, 2007
    Date of Patent: September 1, 2009
    Assignee: General Electric Company
    Inventors: Robert William Bruce, Jerry Donald Schell, Mark Daniel Gorman
  • Patent number: 7544394
    Abstract: In accordance with an embodiment of the invention, an article is provided. The article comprises a substrate comprised of silicon containing material, an environmental barrier coating (EBC) overlying the substrate and a thermal barrier coating (TBC) on the environmental barrier coating. The thermal barrier coating comprising a compound having a rhombohedral phase.
    Type: Grant
    Filed: September 5, 2007
    Date of Patent: June 9, 2009
    Assignee: General Electric Company
    Inventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel, Ramgopal Darolia, Curtis Alan Johnson, Yan Gao, Mark Daniel Gorman
  • Patent number: 7544424
    Abstract: A coating process and system for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating system includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.
    Type: Grant
    Filed: November 30, 2006
    Date of Patent: June 9, 2009
    Assignee: General Electric Company
    Inventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
  • Patent number: 7537806
    Abstract: In accordance with an embodiment of the invention, a thermal barrier coating for inclusion in a thermal barrier coating system is provided. The thermal barrier coating comprises a compound having a rhombohedral phase. In accordance with another embodiment of the invention, a thermal barrier coating is provided that comprises a compound having the formula of: A4B3O12, wherein A is at least one rare earth element; and B is selected from the group consisting of Zr, Hf and mixtures thereof.
    Type: Grant
    Filed: September 5, 2007
    Date of Patent: May 26, 2009
    Assignee: General Electric Company
    Inventors: Brett Allen Rohrer Boutwell, Ramgopal Darolia, Curtis Alan Johnson, Irene Spitsberg, Mark Daniel Gorman, Yan Gao
  • Publication number: 20090061086
    Abstract: A coating process and system suitable for use on components subjected to high temperatures. The coating system includes an overlay coating of predominantly B2 phase rhodium aluminide (RhAl) intermetallic compound containing about 25 to about 90 atomic percent rhodium, about 10 to about 60 atomic percent aluminum, optionally up to a combined total of about 25 atomic percent of one or more platinum group metals chosen from the group consisting of platinum, palladium, ruthenium, and iridium, and up to about 20 atomic percent of the base metal and alloying constituents of the substrate. The RhAl intermetallic coating may serve as an environmental coating, a diffusion barrier layer for an overlying environmental coating, or both, with or without an outer ceramic coating.
    Type: Application
    Filed: April 7, 2008
    Publication date: March 5, 2009
    Applicant: General Electric Company
    Inventors: Liang Jiang, Michael Francis Xavier Gigliotti, JR., Mark Daniel Gorman, Ramgopal Darolia
  • Patent number: 7476453
    Abstract: In accordance with an embodiment of the invention, a thermal barrier coating for inclusion in a thermal barrier coating system is provided. The thermal barrier coating comprises a compound having a rhombohedral phase. In accordance with another embodiment of the invention, a thermal barrier coating is provided that comprises a compound having the formula of: A4B3O12, wherein A is at least one rare earth element; and B is selected from the group consisting of Zr, Hf and mixtures thereof.
    Type: Grant
    Filed: December 6, 2004
    Date of Patent: January 13, 2009
    Assignee: General Electric Company
    Inventors: Brett Allen Rohrer Boutwell, Ramgopal Darolia, Curtis Alan Johnson, Irene Spitsberg, Mark Daniel Gorman, Yan Gao
  • Patent number: 7416790
    Abstract: A coating process and system suitable for use on components subjected to high temperatures. The coating system includes an overlay coating of predominantly B2 phase rhodium aluminide (RhAl) intermetallic compound containing about 25 to about 90 atomic percent rhodium, about 10 to about 60 atomic percent aluminum, optionally up to a combined total of about 25 atomic percent of one or more platinum group metals chosen from the group consisting of platinum, palladium, ruthenium, and iridium, and up to about 20 atomic percent of the base metal and alloying constituents of the substrate. The RhAl intermetallic coating may serve as an environmental coating, a diffusion barrier layer for an overlying environmental coating, or both, with or without an outer ceramic coating.
    Type: Grant
    Filed: December 8, 2006
    Date of Patent: August 26, 2008
    Assignee: General Electric Company
    Inventors: Liang Jiang, Michael Francis Xavier Gigliotti, Jr., Mark Daniel Gorman, Ramgopal Darolia
  • Patent number: 7413778
    Abstract: A method for applying a NiAl based bond coat and a diffusion aluminide coating to a metal substrate comprises, in part, coating a portion of the external surface of the superalloy substrate, by physical vapor deposition with a layer of a NiAl based metal alloy, wherein the deposited NiAl based metal alloy includes a controlled amount of about 6 to 25 weight percent aluminum, wherein the deposited aluminum level of the NiAl based metal alloy is controlled to be about 50-100% of its final level after aluminizing to form a coated external portion; and subsequently, simultaneously aluminizing the coated external portion and a different surface of the superalloy substrate.
    Type: Grant
    Filed: December 5, 2005
    Date of Patent: August 19, 2008
    Assignee: General Electric Company
    Inventors: Mark Daniel Gorman, Brett Allen Boutwell, Robert George Zimmerman, Jr.
  • Publication number: 20080166499
    Abstract: In accordance with an embodiment of the invention, a thermal barrier coating for inclusion in a thermal barrier coating system is provided. The thermal barrier coating comprises a compound having a rhombohedral phase. In accordance with another embodiment of the invention, a thermal barrier coating is provided that comprises a compound having the formula of: A4B3O12, wherein A is at least one rare earth element; and B is selected from the group consisting of Zr, Hf and mixtures thereof.
    Type: Application
    Filed: September 5, 2007
    Publication date: July 10, 2008
    Inventors: Brett Allen Rohrer Boutwell, Ramgopal Darolia, Curtis Alan Johnson, Irene Spitsberg, Mark Daniel Gorman, Yan Gao
  • Publication number: 20080160201
    Abstract: In accordance with an embodiment of the invention, an article is provided. The article comprises a substrate comprised of silicon containing material, an environmental barrier coating (EBC) overlying the substrate and a thermal barrier coating (TBC) on the environmental barrier coating. The thermal barrier coating comprising a compound having a rhombohedral phase.
    Type: Application
    Filed: September 5, 2007
    Publication date: July 3, 2008
    Inventors: Brett Allen Rohrer Boutwell, Irene Spitsberg, Christine Govern, Bangalore A. Nagaraj, Brian Thomas Hazel, Ramgopal Darolia, Curtis Alan Johnson, Yan Gao, Mark Daniel Gorman
  • Publication number: 20080138647
    Abstract: A coating process and system suitable for use on components subjected to high temperatures. The coating system includes an overlay coating of predominantly B2 phase rhodium aluminide (RhAl) intermetallic compound containing about 25 to about 90 atomic percent rhodium, about 10 to about 60 atomic percent aluminum, optionally up to a combined total of about 25 atomic percent of one or more platinum group metals chosen from the group consisting of platinum, palladium, ruthenium, and iridium, and up to about 20 atomic percent of the base metal and alloying constituents of the substrate. The RhAl intermetallic coating may serve as an environmental coating, a diffusion barrier layer for an overlying environmental coating, or both, with or without an outer ceramic coating.
    Type: Application
    Filed: December 8, 2006
    Publication date: June 12, 2008
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Liang Jiang, Michael Francis Xavier Gigliotti, Mark Daniel Gorman, Ramgopal Darolia
  • Publication number: 20080131720
    Abstract: A coating process and system for an article having a substrate formed of a metal alloy that is prone to the formation of a secondary reaction zone (SRZ). The coating system includes an aluminum-containing overlay coating and a stabilizing layer between the overlay coating and the substrate. The overlay coating contains aluminum in an amount greater by atomic percent than the metal alloy of the substrate, such that there is a tendency for aluminum to diffuse from the overlay coating into the substrate. The stabilizing layer is predominantly or entirely formed of at least one platinum group metal (PGM), namely, platinum, rhodium, iridium, and/or palladium. The stabilizing layer is sufficient to inhibit diffusion of aluminum from the overlay coating into the substrate so that the substrate remains essentially free of an SRZ that would be deleterious to the mechanical properties of the alloy.
    Type: Application
    Filed: November 30, 2006
    Publication date: June 5, 2008
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Mark Daniel Gorman, Brian Thomas Hazel, Brett Allen Rohrer Boutwell, Ramgopal Darolia
  • Patent number: 7378159
    Abstract: A protected article has a substrate and a protective structure overlying a surface of the substrate. The protective structure includes a protective layer overlying the surface of the substrate and having an aluminum content greater than that of the substrate, and a bond-coat layer of a bond-coat-layer metal. The bond-coat-layer metal has a bond-coat initial composition having at least about 60 percent by weight platinum, rhodium, palladium, or combinations thereof. There may be a diffusion-barrier layer between the surface of the substrate and the protective layer, and there may be a ceramic thermal barrier coating overlying the bond-coat layer.
    Type: Grant
    Filed: August 20, 2004
    Date of Patent: May 27, 2008
    Assignee: General Electric Company
    Inventors: Mark Daniel Gorman, Ramgopal Darolia