Patents by Inventor Matthew Gold
Matthew Gold 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: 11571762Abstract: A printing method for selectively depositing braze powders on a surface comprises extruding a filament from a nozzle moving relative to a surface, where the filament comprises a flowable carrier mixed with a braze powder. As the nozzle moves, the filament is deposited on the surface in a predetermined pattern defined by the motion of the nozzle relative to the surface; thus, the braze powders are deposited at one or more predetermined locations on the surface.Type: GrantFiled: November 15, 2019Date of Patent: February 7, 2023Assignees: Rolls-Royce North American Technologies Inc., ROLLS-ROYCE CORPORATIONInventors: Matthew Gold, Greg Lopshire, Raymond Xu, Carl Russo
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Patent number: 11565336Abstract: A method for selectively adhering braze powders to a surface comprises applying a braze powder to a surface, and then directing a laser beam onto the braze powder while the laser beam moves along a predetermined path relative to the surface. The laser beam selectively heats the braze powder along the predetermined path such that the braze powder is sintered and bonded to the surface. Thus, a braze deposit is formed at one or more predetermined locations on the surface. After forming the braze deposit, excess braze powder, that is, the braze powder not selectively heated by the laser, is removed from the surface.Type: GrantFiled: November 15, 2019Date of Patent: January 31, 2023Assignees: ROLLS-ROYCE NORTH AMERICAN TECHNOLOGIES INC., ROLLS-ROYCE CORPORATIONInventors: Greg Lopshire, Quinlan Y. Shuck, Matthew Gold, Carl Russo
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Patent number: 11420279Abstract: A method for selectively adhering braze powders to a surface comprises applying a binder material to a surface, depositing a braze powder on the binder material, and then directing a laser beam onto the braze powder while the laser beam moves along a predetermined path relative to the surface. The laser beam selectively heats the braze powder and the binder material along the predetermined path such that the binder material is removed and the braze powder is sintered and bonded to the surface. Thus, a braze deposit is formed at one or more predetermined locations on the surface. After forming the braze deposit, excess braze powder and binder material, that is, the braze powder and binder material not selectively heated by the laser, are removed from the surface.Type: GrantFiled: November 15, 2019Date of Patent: August 23, 2022Assignees: Rolls-Royce Corporation, Rolls-Royce North American Technologies Inc.Inventors: Matthew Gold, Greg Lopshire, Carl Russo
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Publication number: 20210261465Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.Type: ApplicationFiled: May 12, 2021Publication date: August 26, 2021Applicant: OERLIKON METCO (US) INC.Inventors: Jacobus C. DOESBURG, Mitchell R. DORFMAN, Matthew GOLD, Liangde XIE
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Patent number: 11046614Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.Type: GrantFiled: December 8, 2017Date of Patent: June 29, 2021Assignee: OERLIKON METCO (US) INC.Inventors: Jacobus Doesburg, Mitchell Dorfman, Matthew Gold, Liangde Xie
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Publication number: 20210146461Abstract: A method for selectively adhering braze powders to a surface comprises applying a binder material to a surface, depositing a braze powder on the binder material, and then directing a laser beam onto the braze powder while the laser beam moves along a predetermined path relative to the surface. The laser beam selectively heats the braze powder and the binder material along the predetermined path such that the binder material is removed and the braze powder is sintered and bonded to the surface. Thus, a braze deposit is formed at one or more predetermined locations on the surface. After forming the braze deposit, excess braze powder and binder material, that is, the braze powder and binder material not selectively heated by the laser, are removed from the surface.Type: ApplicationFiled: November 15, 2019Publication date: May 20, 2021Inventors: Matthew Gold, Greg Lopshire, Carl Russo
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Publication number: 20210146462Abstract: A method for selectively adhering braze powders to a surface comprises applying a braze powder to a surface, and then directing a laser beam onto the braze powder while the laser beam moves along a predetermined path relative to the surface. The laser beam selectively heats the braze powder along the predetermined path such that the braze powder is sintered and bonded to the surface. Thus, a braze deposit is formed at one or more predetermined locations on the surface. After forming the braze deposit, excess braze powder, that is, the braze powder not selectively heated by the laser, is removed from the surface.Type: ApplicationFiled: November 15, 2019Publication date: May 20, 2021Inventors: Greg LOPSHIRE, Quinlan Y. SHUCK, Matthew GOLD, Carl RUSSO
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Publication number: 20210146459Abstract: A printing method for selectively depositing braze powders on a surface comprises extruding a filament from a nozzle moving relative to a surface, where the filament comprises a flowable carrier mixed with a braze powder. As the nozzle moves, the filament is deposited on the surface in a predetermined pattern defined by the motion of the nozzle relative to the surface; thus, the braze powders are deposited at one or more predetermined locations on the surface.Type: ApplicationFiled: November 15, 2019Publication date: May 20, 2021Inventors: Matthew Gold, Greg Lopshire, Raymond Xu, Carl Russo
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Patent number: 9975812Abstract: Thermal barrier coating made from a thermally sprayable powder that includes yttria stabilized zirconia and hafnia, from 6 to 9 weight percent yttria, and total impurities less than or equal to about 0.1 weight percent. The thermal barrier coating has from about 5 to 250 vertical macro cracks per 25.4 mm length measured along a coating surface and the macro cracks are oriented perpendicular to a surface of a substrate containing said coating.Type: GrantFiled: June 7, 2013Date of Patent: May 22, 2018Assignee: OERLIKON METCO (US) INC.Inventors: Jacobus C. Doesburg, Mitchell Dorfman, Matthew Gold, Liangde Xie
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Publication number: 20180099909Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.Type: ApplicationFiled: December 8, 2017Publication date: April 12, 2018Applicant: OERLIKON METCO (US) INC.Inventors: Jacobus DOESBURG, Mitchell DORFMAN, Matthew GOLD, Liangde XIE
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Publication number: 20130295326Abstract: Thermal barrier coating made from a thermally sprayable powder that includes yttria stabilized zirconia and hafnia, from 6 to 9 weight percent yttria, and total impurities less than or equal to about 0.1 weight percent. The thermal barrier coating has from about 5 to 250 vertical macro cracks per 25.4 mm length measured along a coating surface and the macro cracks are oriented perpendicular to a surface of a substrate containing said coating.Type: ApplicationFiled: June 7, 2013Publication date: November 7, 2013Inventors: Jacobus C. Doesburg, Mitchell Dorfman, Matthew Gold, Liangde Xie
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Patent number: 8187717Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.Type: GrantFiled: December 3, 2010Date of Patent: May 29, 2012Assignee: Sulzer Metco (US) Inc.Inventors: Liangde Xie, Mitchell Dorfman, Richard Schmid, Jacobus C. Doesburg, Matthew Gold
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Publication number: 20120114929Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.Type: ApplicationFiled: December 3, 2010Publication date: May 10, 2012Applicant: SULZER METCO (US), INC.Inventors: Liangde Xie, Mitchell Dorfman, Richard Schmid, Jacobus C. Doesburg, Matthew Gold
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Patent number: 7955707Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.Type: GrantFiled: September 13, 2006Date of Patent: June 7, 2011Assignee: Sulzer Metco (US), Inc.Inventors: Liangde Xie, Mitchell Dorfman, Richard Schmid, Jacobus C. Doesburg, Matthew Gold
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Patent number: 7955708Abstract: The invention is directed to high purity zirconia-based and/or hafnia-based materials and coatings for high temperature cycling applications. Thermal barrier coatings made from the invention high purity material was found to have significantly improved sintering resistance relative to coatings made from current materials of lower purity. The invention materials are high purity zirconia and/or hafnia partially or fully stabilized by one or any combinations of the following stabilizers: yttria, ytterbia, scandia, lanthanide oxide and actinide oxide. Limits for impurity oxide, oxides other than the intended ingredients, that lead to significantly improved sintering resistance were discovered. High purity coating structures suitable for high temperature cycling applications and for application onto a substrate were provided. In one structure, the coating comprises a ceramic matrix, porosity and micro cracks. In another structure, the coating comprises a ceramic matrix, porosity, macro cracks and micro cracks.Type: GrantFiled: September 13, 2006Date of Patent: June 7, 2011Assignee: Sulzer Metco (US), Inc.Inventors: Jacobus C. Doesburg, Liangde Xie, Richard Schmid, Matthew Gold
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Publication number: 20110003119Abstract: The invention is directed to high purity zirconia-based and/or hafnia-based materials and coatings for high temperature cycling applications. Thermal barrier coatings made from the invention high purity material was found to have significantly improved sintering resistance relative to coatings made from current materials of lower purity. The invention materials are high purity zirconia and/or hafnia partially or fully stabilized by one or any combinations of the following stabilizers: yttria, ytterbia, scandia, lanthanide oxide and actinide oxide. Limits for impurity oxide, oxides other than the intended ingredients, that lead to significantly improved sintering resistance were discovered. High purity coating structures suitable for high temperature cycling applications and for application onto a substrate were provided. In one structure, the coating comprises a ceramic matrix, porosity and micro cracks. In another structure, the coating comprises a ceramic matrix, porosity, macro cracks and micro cracks.Type: ApplicationFiled: September 13, 2006Publication date: January 6, 2011Inventors: Jacobus C. Doesburg, Liangde Xie, Richard Schmid, Matthew Gold
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Publication number: 20100311562Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.Type: ApplicationFiled: September 13, 2006Publication date: December 9, 2010Inventors: Liangde Xie, Mitchell Dorfman, Richard Schmid, Jacobus C. Doesburg, Matthew Gold
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Publication number: 20070082131Abstract: The invention is directed to a blended material and method for obtaining thermal barriers for high temperature cycling applications that have both high sintering resistance to achieve a high service lifetime and low thermal conductivity to achieve high operating temperatures. These materials are additionally suited for use in high temperature abradable (rub seal) coatings. The invention provides desired coating structures so that the changes in the coating microstructure over the in-service lifetime are either limited or beneficial.Type: ApplicationFiled: September 13, 2006Publication date: April 12, 2007Inventors: Jacobus Doesburg, Liangde Xie, Richard Schmid, Matthew Gold