Patents by Inventor Robert Alexander Sean Golden
Robert Alexander Sean Golden 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: 11958787Abstract: The disclosure describes braze tape coatings and technique to form articles with differing physical properties in different layers or regions of the article. An example method includes forming a braze tape defining at least one layer that includes a first segment and a second segment. A portion of the second segment in the plane is adjacent to a portion of the first segment in a plane of the layer. The method also includes positioning the braze tape on a surface of a substrate, the plane of the layer of the braze tape being parallel to the surface of the substrate. The method also includes heating the braze tape to melt a constituent of at least one of the first coating material and the second coating material to form a densified coating on the surface of the substrate.Type: GrantFiled: December 11, 2020Date of Patent: April 16, 2024Assignees: Rolls-Royce Corporation, Rolls-Royce High Temperature Composites, Inc.Inventors: Robert Alexander Sean Golden, Sungbo Shim, Li Li, Taylor K. Blair
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Publication number: 20240076245Abstract: An article having a coating system configured to inhibit or prevent crystallization of TGO at the operating temperature of the article. An article includes a substrate defining a surface and a coating layer that includes a dopant configured to inhibit crystallization of amorphous silicon dioxide thermally grown oxide on the bond coat at an operating temperature of the article. The dopant includes a glass modifier. By inhibiting or preventing TGO crystallization, the described coating systems may increase a useable life of the component.Type: ApplicationFiled: September 1, 2022Publication date: March 7, 2024Inventors: Gregory John Kenneth Harrington, Li Li, Robert Alexander Sean Golden
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Patent number: 11845701Abstract: The disclosure describes articles having coating systems configured to inhibit or prevent crystallization of TGO at the operating temperature of the article. An article includes a substrate defining a surface; a bond coat on the surface of the substrate; a coating layer that includes a boron dopant configured to inhibit crystallization of amorphous silicon dioxide thermally grown oxide on the bond coat at an operating temperature of the article. By inhibiting or preventing TGO crystallization, the described coating systems may increase a useable life of the component.Type: GrantFiled: July 21, 2020Date of Patent: December 19, 2023Assignee: Rolls-Royce CorporationInventors: Robert Alexander Sean Golden, Adam Lee Chamberlain, Gregory John Kenneth Harrington
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Patent number: 11702728Abstract: In one example, a method for forming an environmental barrier coating (EBC) and/or abradable coating on a substrate. The method may include depositing a coating on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited coating, wherein the coating includes at least one of an environmental barrier coating (EBC) and an abradable coating. The method further comprises heat treating the as-deposited coating at or above a first temperature for a first period of time following the deposition of the as-deposited coating on the substrate, wherein heat treating the as-deposited coating includes heating the as-deposited coating to or above the first temperature at a controlled rate. The heat treatment may be configured to at least one of decrease the open pores and/or microcracks of the heat-treated coating compared to the as-deposited coating or control a grain size of the heat-treated coating.Type: GrantFiled: May 27, 2020Date of Patent: July 18, 2023Assignee: Rolls-Royce CorporationInventors: Li Li, Gregory John Kenneth Harrington, Robert Alexander Sean Golden
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Patent number: 11624289Abstract: In some examples, the disclosure describes an article and a method of making the same that includes a substrate defining an outer surface, a barrier layer on the outer surface of the substrate, the barrier layer defining a textured surface having a plurality of cells, each cell having a geometry and a depth, and an overlying layer formed on the textured surface of the barrier layer. The barrier layer may be configured to reduce migration of material from the substrate to the overlaying layer to reduce or prevent formation of cristobalite phase thermally grown oxide.Type: GrantFiled: April 21, 2021Date of Patent: April 11, 2023Assignees: Rolls-Royce Corporation, Rolls-Royce High Temperature Composites, Inc.Inventors: Stephanie Gong, Scott Nelson, Sungbo Shim, Li Li, Robert Alexander Sean Golden
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Publication number: 20220371967Abstract: An article may include a substrate, such as a silicon-containing ceramic matrix composite, an environmental barrier coating (EBC) layer on the substrate, and a CMAS-resistant EBC layer on the EBC layer. The EBC layer may include at least one rare-earth disilicate (REDS). The CMAS-resistant EBC layer may include at least one rare-earth monosilicate (REMS) configured to react with CMAS to form crystalline reaction products. The CMAS-resistant EBC layer may include a plurality of vertical cracks extending from a surface of the CMAS-resistant EBC layer at least partially into the CMAS-resistant EBC layer. Additionally, or alternatively, the EBC layer may include a plurality of vertical cracks extending from a surface of the EBC layer into at least a portion of the EBC layer.Type: ApplicationFiled: May 18, 2021Publication date: November 24, 2022Inventors: Li Li, Matthew T. Kush, Robert Alexander Sean Golden, Jun Shi
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Publication number: 20220341335Abstract: In some examples, the disclosure describes an article and a method of making the same that includes a substrate defining an outer surface, a barrier layer on the outer surface of the substrate, the barrier layer defining a textured surface having a plurality of cells, each cell having a geometry and a depth, and an overlying layer formed on the textured surface of the barrier layer. The barrier layer may be configured to reduce migration of material from the substrate to the overlaying layer to reduce or prevent formation of cristobalite phase thermally grown oxide.Type: ApplicationFiled: April 21, 2021Publication date: October 27, 2022Inventors: Stephanie Gong, Scott Nelson, Sungbo Shim, Li Li, Robert Alexander Sean Golden
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Publication number: 20220024827Abstract: The disclosure describes articles having coating systems configured to inhibit or prevent crystallization of TGO at the operating temperature of the article. An article includes a substrate defining a surface; a bond coat on the surface of the substrate; a coating layer that includes a boron dopant configured to inhibit crystallization of amorphous silicon dioxide thermally grown oxide on the bond coat at an operating temperature of the article. By inhibiting or preventing TGO crystallization, the described coating systems may increase a useable life of the component.Type: ApplicationFiled: July 21, 2020Publication date: January 27, 2022Inventors: Robert Alexander Sean Golden, Adam Lee Chamberlain, Gregory John Kenneth Harrington
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Publication number: 20210396150Abstract: An article may include a substrate and a coating system on the substrate. The coating system may include an environmental barrier coating (EBC) layer and a CMAS resistant layer on the EBC layer (e.g., as the top coat of the system). The CMAS layer includes a rare-earth (RE) monosilicate composition including a plurality of RE metal cations, wherein RE monosilicate composition is configured to react with CMAS to form a reaction product including a RE apatite phase with a RE2O3.SiO2 composition, wherein the RE of the RE2O3.SiO2 composition includes at least one of the plurality of RE metal cations of the RE monosilicate.Type: ApplicationFiled: June 17, 2021Publication date: December 23, 2021Inventors: Robert Alexander Sean Golden, Adam Lee Chamberlain
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Publication number: 20210395099Abstract: An article may include a substrate and a coating system on the substrate. The coating system may include a thermal barrier coating (TBC) layer and a CMAS resistant layer on the TBC layer. The CMAS layer includes a rare-earth (RE) monosilicate composition including a plurality of RE metal cations, wherein RE monosilicate composition is configured to react with CMAS to form a reaction product including a RE apatite phase with a RE2O3.SiO2 composition, wherein the RE of the RE2O3.SiO2 composition includes at least one of the plurality of RE metal cations of the RE monosilicate.Type: ApplicationFiled: June 17, 2021Publication date: December 23, 2021Inventors: Robert Alexander Sean Golden, Adam Lee Chamberlain, Matthew R. Gold
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Publication number: 20210221749Abstract: In some examples, a method including depositing a plurality of particles on a ceramic or ceramic matrix composite (CMC) substrate to form a barrier coating on the ceramic or CMC substrate, the plurality of particles including a silica-rich rare earth (RE) disilicate material and a second material, wherein the silica-rich RE disilicate material includes excess silica compared to a stoichiometric RE disilicate material, wherein the barrier coating includes a first domain including the silica-rich RE disilicate material and a second phase, the second phase being disposed at grain boundaries, splat boundaries, or both of the barrier coating.Type: ApplicationFiled: December 21, 2020Publication date: July 22, 2021Inventors: Robert Alexander Sean Golden, Matthew T. Kush
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Publication number: 20210188723Abstract: The disclosure describes braze tape coatings and technique to form articles with differing physical properties in different layers or regions of the article. An example method includes forming a braze tape defining at least one layer that includes a first segment and a second segment. A portion of the second segment in the plane is adjacent to a portion of the first segment in a plane of the layer. The method also includes positioning the braze tape on a surface of a substrate, the plane of the layer of the braze tape being parallel to the surface of the substrate. The method also includes heating the braze tape to melt a constituent of at least one of the first coating material and the second coating material to form a densified coating on the surface of the substrate.Type: ApplicationFiled: December 11, 2020Publication date: June 24, 2021Inventors: Robert Alexander Sean Golden, Sungbo Shim, Li Li, Taylor K. Blair
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Publication number: 20200377990Abstract: In one example, a method for forming an environmental barrier coating (EBC) and/or abradable coating on a substrate. The method may include depositing a coating on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited coating, wherein the coating includes at least one of an environmental barrier coating (EBC) and an abradable coating. The method further comprises heat treating the as-deposited coating at or above a first temperature for a first period of time following the deposition of the as-deposited coating on the substrate, wherein heat treating the as-deposited coating includes heating the as-deposited coating to or above the first temperature at a controlled rate. The heat treatment may be configured to at least one of decrease the open pores and/or microcracks of the heat-treated coating compared to the as-deposited coating or control a grain size of the heat-treated coating.Type: ApplicationFiled: May 27, 2020Publication date: December 3, 2020Inventors: Li Li, Gregory John Kenneth Harrington, Robert Alexander Sean Golden