Patents by Inventor Mitchell R. Dorfman
Mitchell R. Dorfman 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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Publication number: 20240109813Abstract: A method of applying an environmental barrier coating and an environmental barrier coating. The method includes applying a high apparent density powder via a high temperature and high velocity (HTHV) process. The high apparent density powder comprises at least one of rare earth silicates; mullite or alkaline silicate.Type: ApplicationFiled: February 4, 2022Publication date: April 4, 2024Inventors: Dianying CHEN, Aaron PEGLER, Gopal DWIVEDI, Mitchell R DORFMAN
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Patent number: 11697871Abstract: Articles coated with a porous, segmented thermal barrier coating. The coating described has a density less than about 88% of the theoretical density. Multi-layer articles and methods of applying the thermal barrier coatings to an article are also described.Type: GrantFiled: February 19, 2015Date of Patent: July 11, 2023Assignee: OERLIKON METCO (US) INC.Inventors: Dianying Chen, Christopher G. Dambra, Mitchell R. Dorfman
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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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Publication number: 20210140339Abstract: An erosion and CMAS resistant coating arranged on a TBC coated substrate and including at least one porous vertically cracked (PVC) coating layer providing lower thermal conductivity and being disposed over a layer of MCrAlY wherein M represents Ni, Co or their combinations. At least one dense vertically cracked (DVC) erosion and CMAS resistant coating layer is deposited over the at least one PVC coating layer.Type: ApplicationFiled: April 8, 2019Publication date: May 13, 2021Applicant: OERLIKON METCO (US) INC.Inventors: Dianying CHEN, Christopher G. DAMBRA, Mitchell R. DORFMAN
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Publication number: 20160348226Abstract: Articles coated with a porous, segmented thermal barrier coating. The coating described has a density less than about 88% of the theoretical density. Multi-layer articles and methods of applying the thermal barrier coatings to an article are also described.Type: ApplicationFiled: February 19, 2015Publication date: December 1, 2016Applicant: OERLIKON METCO (US) INC.Inventors: Dianying CHEN, Christopher G. DAMBRA, Mitchell R. DORFMAN
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Patent number: 9103013Abstract: A thermal spray powder having a first component A mechanically blended with a second component B, wherein the first component A is a metal or metal composite, preferably at least one of Ni—Cr—Al clad ABN, Ni—Cr—Al clad HBN, Ni—Cr—Al clad agglomerated hexagonal boron nitride powder with organic binder, Ni—Cr—Al agglomerated hexagonal boron nitride powder with inorganic binder, an MCrAlY type powder where M is at least one of Ni, Co, Fe, and wherein component B is a polymer clad with at least one of nickel, nickel alloys, nickel chrome alloys, nickel chrome aluminum alloys, nickel aluminum alloys, cobalt and cobalt alloys. The result is a thermal spray powder of four distinctly different phases making the powder a four-phase blend.Type: GrantFiled: January 25, 2011Date of Patent: August 11, 2015Assignee: OERLIKON METCO (US) INC.Inventors: Mitchell R. Dorfman, Chris Dambra, Walter Pietrowicz, Scott Wilson, Daniel Garcia, Petr Fiala, Eric Kozculab, Dieter Rudolf Sporer, Omar B. Al-Sabouni, Montia C. Nestler, Eric J. Reents, Gustavo Arevalo
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Patent number: 8603930Abstract: The present invention provides a high-purity fused and crushed stabilized zirconia powder. The powder—with or without further processing, such as plasma spheroidization—is used in thermal spray applications of thermal barrier coatings (TBCs) and high-temperature abradables. The resulting coatings have a significantly improved high temperature sintering resistance, which will enhance the durability and thermal insulation effect of the coating.Type: GrantFiled: April 25, 2007Date of Patent: December 10, 2013Assignee: Sulzer Metco (US), Inc.Inventors: Jacobus C. Doesburg, Mitchell R. Dorfman, Liangde Xie
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Publication number: 20120295825Abstract: A thermal spray powder having a first component A mechanically blended with a second component B, wherein the first component A is a metal or metal composite, preferably at least one of Ni—Cr—Al clad ABN, Ni—Cr—Al clad HBN, Ni—Cr—Al clad agglomerated hexagonal boron nitride powder with organic binder, Ni—Cr—Al agglomerated hexagonal boron nitride powder with inorganic binder, an MCrAlY type powder where M is at least one of Ni, Co, Fe, and wherein component B is a polymer clad with at least one of nickel, nickel alloys, nickel chrome alloys, nickel chrome aluminum alloys, nickel aluminum alloys, cobalt and cobalt alloys. The result is a thermal spray powder of four distinctly different phases making the powder a four-phase blend.Type: ApplicationFiled: January 25, 2011Publication date: November 22, 2012Applicant: SULZER METCO (US) INC.Inventors: Mitchell R. Dorfman, Chris Dambra, Walter Pietrowicz, Scott Wilson, Daniel Garcia, Petr Fiala, Eric Kozculab, Dieter Rudolf Sporer, Omar B. Al-Sabouni, Montia C. Nestler, Eric J. Reents, Gustavo Arevalo
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Publication number: 20120177836Abstract: The present invention provides a high-purity fused and crushed stabilized zirconia powder. The powder—with or without further processing, such as plasma spheroidization—is used in thermal spray applications of thermal barrier coatings (TBCs) and high-temperature abradables. The resulting coatings have a significantly improved high temperature sintering resistance, which will enhance the durability and thermal insulation effect of the coating.Type: ApplicationFiled: April 25, 2007Publication date: July 12, 2012Inventors: Jacobus C. Doesburg, Mitchell R. Dorfman, Liangde Xie
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Patent number: 7981530Abstract: Ceramic abradable materials, in particular thermally sprayable ceramic abradable powder materials, and abradable seals formed by thermally spraying the materials include dysprosia (Dy2O3) and zirconia (ZrO2). Coatings are porous whereby the porosity, in part, is induced by plastic or fugitive phases. Abradable seal coatings comprising dysprosia and zirconia exhibit improved thermal shock and sintering resistance and can be worn into tolerance by untreated, bare turbine blades, at least in certain regimes of relative blade speed and coating porosity. Ceramic abradable seal coatings comprising dysprosia and zirconia can be used up to 1200° C.Type: GrantFiled: June 7, 2007Date of Patent: July 19, 2011Assignee: Sulzer Metco (US), Inc.Inventors: Dieter R. Sporer, Ulrike Taeck, Mitchell R. Dorfman, Andrew R. Nicoll, Massimo Giannozzi, Iacopo Giovannetti
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Patent number: 7799716Abstract: The present invention provides a low density and porous zirconia (ZrO2) powder partially alloyed with one or more of yttria, scandia, dysprosia, ytterbia, or any of the oxides of lanthanide or actinide. The total amount of alloying oxides should be less than about 30 weight percent. The powder is manufactured by controlled sintering or light plasma densification of physically agglomerated, or chemically derived zirconia composite powder that contains proper amounts of yttria, scandia, dysprosia, ytterbia, or any of the oxides of lanthanide or actinide, or any combination of the aforementioned oxides. The resulting coating from use of the inventive powder has a monoclinic phase content of less than 5 percent.Type: GrantFiled: March 3, 2006Date of Patent: September 21, 2010Assignee: Sulzer Metco (US), Inc.Inventors: Michael Mueller, Mitchell R. Dorfman, Liangde Xie
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Publication number: 20080124548Abstract: Ceramic abradable materials, in particular thermally sprayable ceramic abradable powder materials, and abradable seals formed by thermally spraying the materials include dysprosia (Dy2O3) and zirconia (ZrO2). Coatings are porous whereby the porosity, in part, is induced by plastic or fugitive phases. Abradable seal coatings comprising dysprosia and zirconia exhibit improved thermal shock and sintering resistance and can be worn into tolerance by untreated, bare turbine blades, at least in certain regimes of relative blade speed and coating porosity. Ceramic abradable seal coatings comprising dysprosia and zirconia can be used up to 1200° C.Type: ApplicationFiled: June 7, 2007Publication date: May 29, 2008Inventors: Dieter R. Sporer, Ulrike Taeck, Mitchell R. Dorfman, Andrew R. Nicoll, Massimo Giannozzi, Iacopo Giovannetti
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Patent number: 6869550Abstract: A pre-alloyed stabilized zirconia powder suitable for use in thermal barrier applications is formed by alloying zirconia with a stabilizer, such as yttria, and processing the alloyed stabilized zirconia to form a very fine powder. The raw powder is then spray-dried to produce an agglomerated powder having an average particle size suitable for use in spray coating applications. The resulting powder can be used in a thermal-spray application to produce a porous thermal barrier coating having a substantially decreased thermal conductivity when compared to conventional TB coatings, such those produced using plasma-densified powders.Type: GrantFiled: December 7, 2001Date of Patent: March 22, 2005Assignee: Sulzer Metco (US) Inc.Inventors: Mitchell R. Dorfman, Luis F. Correa, Christopher G. Dambra, Komal Laul, Richard K. Schmid
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Publication number: 20040197580Abstract: A pre-alloyed stabilized zirconia powder suitable for use in thermal barrier applications is formed by alloying zirconia with a stabilizer, such as yttria, and processing the alloyed stabilized zirconia to form a very fine powder. The raw powder is then spray-dried to produce an agglomerated powder having an average particle size suitable for use in spray coating applications. The resulting powder can be used in a thermal-spray application to produce a porous thermal barrier coating having a substantially decreased thermal conductivity when compared to conventional TB coatings, such those produced using plasma-densified powders.Type: ApplicationFiled: December 7, 2001Publication date: October 7, 2004Inventors: Mitchell R. Dorfman, Luis F. Correa, Christopher G. Dambra, Komal Laul, Richard K. Schmid
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Publication number: 20040005452Abstract: An improved method of forming an abradable thermal barrier coating comprises providing a spray-dried powder of M-CrAlY and a solid lubricant, such as CoNiCrAlY—BN. Unlike powders provided for use with plasma spray guns, the powder is essentially free of polyester or other organic fugitive additives provided to increase porosity. The powder is applied using a combustion spray process and results in a M-CrAlY abradable coating that has an average porosity comparable to that of a plasma-applied coating but with smaller and more uniform pore distribution, and without requiring post-application heat treatments to remove fugitive materials. Deposition efficiency is also increased.Type: ApplicationFiled: January 14, 2003Publication date: January 8, 2004Inventors: Mitchell R. Dorfman, James Mallon, Richard K. Schmid
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Patent number: 6524704Abstract: A powder of dicalcium silicate is made by spray drying calcia and silica with incorporation of sodium and phosphorus or stabilized zirconia. The spray dried powder is sintered to form a thermal spray powder. Sprayed coatings have a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coatings are stable in thermal cycling and a hot corrosive environment.Type: GrantFiled: October 4, 2000Date of Patent: February 25, 2003Assignee: Sulzer Metco (US) Inc.Inventors: Xiaohan Wei, Mitchell R. Dorfman, Luis F. Correa, Franz Jansen, John Peters
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Patent number: 6503576Abstract: A high velocity oxygen fuel thermal spray powder comprising a superalloy having the formula MCrAlY—X, wherein M is at least one metal taken from the group consisting of nickel, cobalt, and iron; X is at least one reactive element taken from the group consisting of hafnium, rhenium, lanthanum, and tantalum; and yttrium is present in levels greater than 1% by weight of the total composition and up to about 6% by weight of the total composition. In addition, the powder may be blended with an agglomeration of M′CrAlY and a ceramic, wherein M′ is at least one metal taken from the group consisting of nickel, cobalt, and iron. The invention offers improved high temperature oxidation, corrosion and creep resistance.Type: GrantFiled: October 5, 2001Date of Patent: January 7, 2003Assignee: Sulzer Metco (US) Inc.Inventors: Lysa Russo, Mitchell R. Dorfman, Kerry LaPierre
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Publication number: 20020194956Abstract: A high velocity oxygen fuel thermal spray powder comprising a superalloy having the formula MCrAlY-X, wherein M is at least one metal taken from the group consisting of nickel, cobalt, and iron; X is at least one reactive element taken from the group consisting of hafnium, rhenium, lanthanum, and tantalum; and yttrium is present in levels greater than 1% by weight of the total composition and up to about 6% by weight of the total composition. In addition, the powder may be blended with an agglomeration of M′CrAlY and a ceramic, wherein M′ is at least one metal taken from the group consisting of nickel, cobalt, and iron. The invention offers improved high temperature oxidation, corrosion and creep resistance.Type: ApplicationFiled: October 5, 2001Publication date: December 26, 2002Applicant: Sulzer Metco (US) Inc.Inventors: Lysa Russo, Mitchell R. Dorfman, Kerry LaPierre
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Patent number: 6346134Abstract: A high velocity oxygen fuel thermal spray powder comprising a superalloy having the formula MCrAlY—X, wherein M is at least one metal taken from the group consisting of nickel, cobalt, and iron; X is at least one reactive element taken from the group consisting of hafnium, rhenium, lanthanum, and tantalum; and yttrium is present in levels greater than 1% by weight of the total composition and up to about 6% by weight of the total composition. In addition, the powder may be blended with an agglomeration of M′CrAlY and a ceramic, wherein M′ is at least one metal taken from the group consisting of nickel, cobalt, and iron. The invention offers improved high temperature oxidation, corrosion and creep resistance.Type: GrantFiled: March 27, 2000Date of Patent: February 12, 2002Assignee: Sulzer Metco (US) Inc.Inventors: Lysa Russo, Mitchell R. Dorfman, Kerry LaPierre
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Patent number: 6254704Abstract: A thermal spray powder consists of nickel, chromium and carbon. The chromium consists of a first portion and a second portion, the nickel being alloyed with the first portion in an alloy matrix. The second portion and the carbon are combined into chromium carbide substantially as Cr3C2 or Cr7C3 or a combination thereof, with the chromium carbide being in the form of precipitates between 0.1 &mgr;m and 5 &mgr;m distributed uniformly in the alloy matrix.Type: GrantFiled: January 27, 2000Date of Patent: July 3, 2001Assignee: Sulzer Metco (US) Inc.Inventors: Komal Laul, Mitchell R. Dorfman, Ronald Eugene Somoskey, Jr.