Spray Coating Utilizing Flame Or Plasma Heat (e.g., Flame Spraying, Etc.) Patents (Class 427/446)
  • Patent number: 10889507
    Abstract: A process for producing a metal oxide powder comprising: providing a precursor solution or dispersion containing a metal complex; spraying the precursor solution on to a heated substrate in the presence of water, thereby depositing material on the substrate; drying the deposited material; and removing the deposited material from the substrate to produce the metal oxide powder.
    Type: Grant
    Filed: February 6, 2017
    Date of Patent: January 12, 2021
    Inventors: Peter Edwards, Jonathan Dilworth, Vladimir Kuznetsov, Catherine Hayes
  • Patent number: 10858725
    Abstract: A method that includes introducing a suspension comprising a coating material and a carrier into a heated plume of a thermal spray device. The coating material may include silicon or a silicon alloy. The method further includes directing the coating material using the heated plume toward a substrate that includes a ceramic or a ceramic matrix composite and depositing the coating material to form a bond coat directly on the substrate such that the bond coat defines a porosity of less than about 3 percent by volume.
    Type: Grant
    Filed: June 25, 2018
    Date of Patent: December 8, 2020
    Assignees: Rolls-Royce Corporation, Rolls-Royce North American Technologies, Inc.
    Inventors: Li Li, Stephanie Gong, Matthew R. Gold, Ann Bolcavage
  • Patent number: 10793942
    Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.
    Type: Grant
    Filed: August 2, 2017
    Date of Patent: October 6, 2020
    Assignee: Raytheon Technologies Corporation
    Inventors: Brian T Hazel, Joseph A DePalma, Jessica L Serra, Henry H Thayer, Donn R Blankenship, Mario P Bochiechio, Paul H Zajchowski
  • Patent number: 10775216
    Abstract: Provided is a physical-quantity detecting device having high reliability by preventing water droplets from attaching to a diaphragm area. A physical-quantity detecting device according to the present invention includes: a circuit board having provided thereon at least one detecting unit that detects a physical quantity of gas to be measured that passes through a main passage and also having provided thereon a circuit unit that executes computational processing on the physical quantity detected by the detecting unit; and a housing accommodating the circuit board, wherein the physical-quantity detecting unit on the circuit board is constructed to be exposed to the main passage. Furthermore, convex projections are provided around a through hole directly communicating with the physical-quantity detecting unit implemented on the circuit board.
    Type: Grant
    Filed: October 5, 2016
    Date of Patent: September 15, 2020
    Inventors: Hiroyuki Abe, Takayuki Yogo
  • Patent number: 10745793
    Abstract: A ceramic coating process comprises introducing a suspension including a fine ceramic particulate suspended in a liquid carrier into a plasma torch. The method includes melting the fine ceramic particulate in the plasma torch; propelling the fine ceramic particulate toward a substrate; and forming a coating on the substrate, the coating comprises splats of the fine ceramic particulate.
    Type: Grant
    Filed: June 4, 2015
    Date of Patent: August 18, 2020
    Assignee: Raytheon Technologies Corporation
    Inventors: Brian T Hazel, Mario P Bochiechio
  • Patent number: 10626883
    Abstract: A method of making a sheath for an airfoil may include the steps of forming an upper sleeve and a lower sleeve, and forming a central portion bonded to the upper sleeve and the lower sleeve. The central portion may be formed by depositing a material on the upper sleeve and the lower sleeve. A portion of the material may be removed from at least one of the central portion, the upper sleeve, or the lower sleeve. The sheath may include a first flank, a central portion bonded to the first flank, and a second flank bonded to the central portion. The central portion may have a substantially uniform microstructure resulting from additive manufacturing.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: April 21, 2020
    Inventors: Sergey Mironets, Daniel Ursenbach
  • Patent number: 10468265
    Abstract: A method for synchronous wet etching processing of differential microstructures, including the following steps: step a: performing photoetching on a processing surface of a workpiece to be processed to develop the workpiece; step b: affixing a mask to a surface opposite to the processing surface of the workpiece; step c: continuously cooling the mask; step d: placing the cooled mask and the workpiece in a wet etching device; and adding an etchant to the processing surface of the workpiece to start etching; step e: removing the mask and the workpiece from the wet etching device after the set etching time; separating the mask and the workpiece to obtain a workpiece with a etching structure. A temperature difference is formed between the pattern area to be processed and the retaining area.
    Type: Grant
    Filed: April 15, 2019
    Date of Patent: November 5, 2019
    Assignee: Guangdong University of Technology
    Inventors: Xin Chen, Yun Chen, Dachuang Shi, Xun Chen, Qiang Liu, Jian Gao, Chengqiang Cui
  • Patent number: 10422028
    Abstract: A method for conditioning a ceramic layer with a thickness of less than 150 ?m over a substrate is provided. The ceramic layer is cleaned. A region of the ceramic layer is scanned with a pulsed excimer laser beam at a repetition rate of 3-300 Hz.
    Type: Grant
    Filed: December 7, 2015
    Date of Patent: September 24, 2019
    Assignee: Lam Research Corporation
    Inventors: Lihua Li Huang, Hong Shih, Siwen Li
  • Patent number: 10424466
    Abstract: The present disclosure provides a method for inspecting a shower plate of a plasma processing apparatus. In the plasma processing apparatus, a gas ejection unit includes a shower plate. A plurality of gas ejection holes are formed on the shower plate. This method includes (i) setting a flow rate of gas output from a first flow rate controller, and (ii) acquiring a measurement value indicating a pressure in a flow path inside a second pressure control type flow rate controller by using a pressure gauge of the second flow rate controller in a state where the gas output from the first flow rate controller at the set flow rate is supplied to the gas ejection unit and branched between the first flow rate controller and the gas ejection unit so as to be supplied to the flow path inside the second flow rate controller.
    Type: Grant
    Filed: August 18, 2017
    Date of Patent: September 24, 2019
    Inventors: Norihiko Amikura, Risako Miyoshi
  • Patent number: 10267173
    Abstract: A turbine shroud of a turbine of a gas turbine engine and methods of making the turbine shroud are disclosed. The turbine shroud is configured to direct products of a combustion reaction in a combustor of the gas turbine engine toward a plurality of rotatable turbine blades of the turbine to cause the plurality of turbine blades to rotate.
    Type: Grant
    Filed: September 17, 2015
    Date of Patent: April 23, 2019
    Assignee: Rolls-Royce Corporation
    Inventors: Michael D. Webb, Neil A. Clayton
  • Patent number: 10180503
    Abstract: The present disclosure relates to a process for fabricating a crystalline scintillator material with a structure of elpasolite type of theoretical composition A2BC(1-y)MyX(6-y) wherein: A is chosen from among Cs, Rb, K, Na, B is chosen from among Li, K, Na, C is chosen from among the rare earths, Al, Ga, M is chosen from among the alkaline earths, X is chosen from among F, Cl, Br, I, y representing the atomic fraction of substitution of C by M and being in the range extending from 0 to 0.05, comprising its crystallization by cooling from a melt bath comprising r moles of A and s moles of B, the melt bath in contact with the material containing A and B in such a way that 2s/r is above 1. The process shows an improved fabrication yield. Moreover, the crystals obtained can have compositions closer to stoichiometry and have improved scintillation properties.
    Type: Grant
    Filed: April 23, 2018
    Date of Patent: January 15, 2019
    Assignee: Saint-Gobain Cristaux et Detecteurs
    Inventors: Vladimir Ouspenski, Samuel Blahuta, Raphaël Huchet, Julien Lejay
  • Patent number: 10092919
    Abstract: A method of detecting the presence of a product sprayed onto an application surface, in which the product to be applied to the application surface is sprayed onto a target zone of the application surface in pulses. Before spraying the product it is heated to a temperature higher than a predetermined temperature value. After spraying the product, a value of a parameter representing the temperature of the target zone is measured remotely, and the value of that parameter is compared to a reference value of that parameter. A detection installation including pulsed spraying by way of forming part of a device shared with the heating element.
    Type: Grant
    Filed: May 12, 2017
    Date of Patent: October 9, 2018
    Assignee: Nemera La Verpillière S.A.S.
    Inventor: Pierre Pintus
  • Patent number: 9987608
    Abstract: Methods and apparatuses are provided for the production of homogeneous dispersions of nanostructures within a matrix, which may be used as precursors of carbon-reinforced or boron nitride-reinforced composite materials. An apparatus for producing a nanostructure dispersion comprises a reactor and a mixing chamber, wherein the reactor is configured to produce an aerosol of nanostructures and is in fluidic communication with the mixing chamber. A matrix material is provided in the mixing chamber, and the aerosol of nanostructures can disperse into the matrix material to form a nanostructure dispersion. The apparatus may further comprise a matrix tank comprising a matrix material, wherein the matrix material is transferred to the mixing chamber. An aerosol of matrix particles may be produced from the matrix material and provided in the mixing chamber, so as to produce a fine dispersion of nanostructures in the matrix. The apparatus may be configured to continuously produce a nanostructure dispersion.
    Type: Grant
    Filed: September 18, 2015
    Date of Patent: June 5, 2018
    Inventor: Elena Pigos
  • Patent number: 9951426
    Abstract: A method for depositing a layer includes repeatedly performing a unit deposition process until the layer on a deposition target reaches a predetermined thickness. The unit deposition process includes (depositing the layer on the deposition target by a cold spray process while the deposition target is heated by a heater and heat treating the deposition target after the depositing.
    Type: Grant
    Filed: May 20, 2013
    Date of Patent: April 24, 2018
    Inventors: Makoto Saito, Noriyuki Hiramatsu, Akira Fukushima
  • Patent number: 9903036
    Abstract: A method for manufacturing rotogravure cylinders with a cylinder base made of aluminum. The method involves the coating of the cylinder surface with high velocity spraying, the copper plating in an appropriate solution, the engraving of the cylinder, and the hardening of the cylinder by chromium plating. The spraying process is accomplished by High-Velocity Air-Fuel or High-Velocity Oxygen-Fuel thermal spraying which leads to less surface porosity, better adhesion of the copper substrate and better dimensional accuracy.
    Type: Grant
    Filed: October 10, 2013
    Date of Patent: February 27, 2018
    Assignee: Paramount International Services
    Inventor: Ioannis Ioannou
  • Patent number: 9870840
    Abstract: According to example embodiments, a metallic glass includes aluminum (Al), a first element group, and a second element group. The first element group includes at least one of a transition metal and a rare earth element. The second element group includes at least one of an alkaline metal, an alkaline-earth metal, a semi-metal, and a non-metal. The second element group and aluminum have an electronegativity difference of greater than or equal to about 0.25. The second element group is included less than or equal to about 3 at % of the metallic glass, based on the total amount of the aluminum (Al), the first element group, and the second element group. A conductive paste and/or an electrode of an electronic device may be formed using the metallic glass.
    Type: Grant
    Filed: January 2, 2014
    Date of Patent: January 16, 2018
    Assignees: Samsung Electronics Co., Ltd., Yonsi University, University-Industry Foundation (UIF)
    Inventors: Jin Man Park, Keum Hwan Park, Eun Sung Lee, Suk Jun Kim, Se Yun Kim, Sang Soo Jee, Do-hyang Kim
  • Patent number: 9790581
    Abstract: A component for a semiconductor processing chamber, the component including a substrate and a coating layer provided on a surface of the substrate, wherein the coating layer includes at least a first coating layer having a thermal emissivity of more than 0.98 to 1, having plasma resistance, and having a color value L in a range of 35 to 40 through a thickness direction thereof.
    Type: Grant
    Filed: December 8, 2014
    Date of Patent: October 17, 2017
    Assignee: FM Industries, Inc.
    Inventors: Mahmood Naim, David Hammerich
  • Patent number: 9638693
    Abstract: The invention relates to a method for producing a nanoporous layer on a substrate.
    Type: Grant
    Filed: October 4, 2013
    Date of Patent: May 2, 2017
    Inventors: Bernhard Wolfrum, Alexey Yakushenko, Andreas Offenhaeusser, Dirk Mayer
  • Patent number: 9536642
    Abstract: A high-temperature insulation assembly for use in high-temperature electrical machines and a method for forming a high-temperature insulation assembly for insulating conducting material in a high-temperature electrical machine. The assembly includes a polymeric film and at least one ceramic coating disposed on the polymeric film. The polymeric film is disposed over conductive wiring or used as a conductor winding insulator for phase separation and slot liner.
    Type: Grant
    Filed: October 10, 2014
    Date of Patent: January 3, 2017
    Assignee: General Electric Company
    Inventors: Weijun Yin, Min Yan, Ri-An Zhao
  • Patent number: 9354190
    Abstract: Apparatus and method for monitoring and quantifying progression of a structural anomaly, such as crack, over a surface of a component (12) in a high temperature environment of a combustion turbine engine The apparatus may include an electrically-insulating layer (14) formed at least over a portion of the surface of the component of the combustion turbine engine. At least a first detection leg (16) may be disposed on the electrically-insulating layer The first detection leg may be adapted to operate under a desired sensing modality from a bi-modal sensing scheme, such as may be implemented in one sensing modality by way of monitoring changes of an electrical parameter in an electrical circuit formed by the detection leg The sensing scheme may also be implemented by way of imaging radiance energy emitted by the detection leg.
    Type: Grant
    Filed: January 27, 2014
    Date of Patent: May 31, 2016
    Assignee: SIEMENS ENERGY, INC.
    Inventors: Thomas F. Quinn, Anand A. Kulkarni, James F. Landy
  • Patent number: 9355855
    Abstract: The present invention provides a plasma etching apparatus component 1 includes a base material 10 and an yttrium oxide coating 20 formed by an impact sintering process and configured to cover a surface of the base material. The yttrium oxide coating 20 contains at least one of particulate portions and non-particulate portions. The yttrium oxide coating 20 has a film thickness of 10 ?m or above and a film density of 90% or above. The particulate portions have an area coverage ratio of 0 to 80% and the non-particulate portions have an area coverage ratio of 20 to 100%.
    Type: Grant
    Filed: November 29, 2011
    Date of Patent: May 31, 2016
    Inventors: Michio Sato, Takashi Hino, Takashi Rokutanda, Masashi Nakatani
  • Patent number: 9309587
    Abstract: A plasma spray nozzle is provided. Owing to their high degree of wear, previous plasma spray nozzles were not suitable for the coating of components for which long coating times were necessary. The coating times may be reduced considerably by the triple injection of powder into the inner channel through the plasma spray nozzle.
    Type: Grant
    Filed: August 7, 2013
    Date of Patent: April 12, 2016
    Inventors: Mario Felkel, Heiko Gruner, Francis Ladru
  • Patent number: 9299505
    Abstract: In one embodiment of the invention, a method of forming an energy storage device is described in which a porous structure of an electrically conductive substrate is measured in-situ while being electrochemically etched in an electrochemical etching bath until a predetermined value is obtained, at which point the electrically conductive substrate may be removed from the electrochemical etching bath. In another embodiment, a method of forming an energy storage device is described in which an electrically conductive porous structure is measured to determine the energy storage capacity of the electrically conductive porous structure. The energy storage capacity of the electrically conductive porous structure is then reduced until a predetermined energy storage capacity value is obtained.
    Type: Grant
    Filed: December 14, 2011
    Date of Patent: March 29, 2016
    Assignee: Intel Corporation
    Inventors: Eric C. Hannah, Cary L. Pint, Charles W. Holzwarth, John L. Gustafson
  • Patent number: 9046221
    Abstract: A process to create a collision in controlled conditions between a stream of gas and particles and a target includes the generation of a stream of gas and particles, of given composition, in the form of a unidirectional beam, using a supersonic burner comprising a combustion chamber and a gas gun, the combustion chamber being fed with a set of fluids comprising a set of gases comprising an oxidizer, and a specific liquid fuel. The generation of a collision between the beam and the target includes the adjustment of the fuel flow, the flow of each gas and the adjustment of the distance between the burner and the target, so as to obtain at the impact point the desired values of the following parameters: (i) the gas temperature or the temperature of the target, and (ii) the gas speed.
    Type: Grant
    Filed: December 19, 2012
    Date of Patent: June 2, 2015
    Inventors: Michel Moliere, Christophe Verdy
  • Publication number: 20150147572
    Abstract: A powder material of the present invention contains ceramic-metal composite particles, wherein at least a part of the composite particles exhibit no breaking point in a stress-strain diagram obtained by applying a compressive load that increases up to a maximum value of 10 mN or more at a loading rate of 15.0 mN/s or less.
    Type: Application
    Filed: May 17, 2013
    Publication date: May 28, 2015
    Inventors: Kazuto Sato, Hiroaki Hattori, Junya Yamada
  • Publication number: 20150147621
    Abstract: A method for preparing an electrolyte separator for an electrochemical device is described. The method includes the step of applying a beta?-alumina coating composition, or a precursor thereof, to a porous substrate, by an atmospheric, thermal spray technique. An electrochemical device is also described. Some of these devices include an anode, a cathode, and an electrolyte separator disposed between the anode and the cathode. The separator includes a thermally-sprayed layer of beta?-alumina, disposed on a porous substrate. The electrochemical device can be used as an energy storage system, or for other types of end uses.
    Type: Application
    Filed: November 26, 2013
    Publication date: May 28, 2015
    Applicant: General Electric Company
    Inventors: Todd Michael Striker, Richard Louis Hart, Matthew Joseph Alinger, Leonardo Ajdelsztajn
  • Patent number: 9032903
    Abstract: Proposed is a device for coating substrates by means of high-velocity flame spraying. The device comprises a combustion chamber (4), a first fuel feeder (L1) for feeding a liquid or gaseous fuel as well as at least one gas feeder for feeding an oxidative gas. The devise comprises furthermore a second fuel feeder (L5) for feeding a liquid or gaseous fuel as well as at least one further gas feeder for feeding a gas. Both the first gas feeder and the two fuel feeders (L1, L5) port into a common combustion chamber (4). In addition, means 24, 28 are provided for independent control of the fuel feed into the two fuel feeders (L1, L5).
    Type: Grant
    Filed: April 26, 2011
    Date of Patent: May 19, 2015
    Assignee: AMT AG
    Inventor: Silvano Keller
  • Publication number: 20150132539
    Abstract: A coated device comprising a body, a coating on at least a portion of a surface of the body, wherein the coating comprises, a terminal layer, and at least one underlayer positioned between the terminal layer and the body, the underlayer comprising a hardness of greater than 61 HRc, wherein prior to the addition of the terminal layer, at least one of the body and the underlayer is polished to a surface roughness of less than or equal to 1.0 micrometer Ra.
    Type: Application
    Filed: August 28, 2014
    Publication date: May 14, 2015
    Inventors: Jeffrey R. Bailey, Srinivasan Rajagopalan, Mehmet Deniz Ertas, Adnan Ozekcin, Bo Zhao
  • Publication number: 20150125618
    Abstract: A metal wood golf club with a striking face portion made from more than one material is disclosed. More specifically, due to the unique construction of the striking face portion having multiple materials, the present invention utilizes bonding spray deposition process to achieve the desirable bond between the more than one materials used to form the striking face. The striking face portion is formed by creating a chip insert type material utilizing the spray deposition process that is made from a secondary material that is different from the remainder of the striking face portion substantially near a geometric center of the striking face portion; wherein the secondary material has a higher Young's modulus than the remainder of the striking face portion.
    Type: Application
    Filed: January 2, 2015
    Publication date: May 7, 2015
    Inventors: Uday V. Deshmukh, Charles E. Golden
  • Publication number: 20150122079
    Abstract: A component of a rotary wing aircraft is provided including a surface configured to contact another component of the rotary wing aircraft such that the surface is susceptible to corrosion and/or pitting. The surface has an area from which a portion of material was removed. A structural deposit is formed by cold spraying one or more layers of powdered material within the area. The structural deposit is configured to carry a load applied to the component.
    Type: Application
    Filed: November 6, 2013
    Publication date: May 7, 2015
    Applicant: Sikorsky Aircraft Corporation
    Inventors: Eric K. Hansen, James Sullivan, Anthony G. Chory, JinKyu Choi, Michael R. Robbins
  • Patent number: 9023419
    Abstract: A high-purity porous metal coating is formed over a substrate by thermal spraying a metal coating material over the desired portion of the substrate in an atmospheric air environment. The metal coating material may react with the atmosphere to cause impurities in the applied coating. The impurity-rich portion of the applied coating is subsequently removed to form the high-purity porous metal coating. Process steps are included that cause the impurity-rich portion of the applied coating to be a surface portion that is removable to arrive at the high-purity coating. A protective shroud may be used to limit the amount of impurity imparted to the applied coating and/or a getter material may be employed to continually bring impurities toward the surface of the coated substrate during coating.
    Type: Grant
    Filed: November 16, 2012
    Date of Patent: May 5, 2015
    Assignee: Hitemco Medical Application Inc.
    Inventors: Michael Meehan, Jinlong Wang, John Whalen, Edwin Garafalo, Rick Montalbano
  • Publication number: 20150116889
    Abstract: An electrostatic chuck and a manufacturing method are disclosed in which drawbacks of using an adhesive are not existent and a freedom degree of design is high. The electrostatic chuck includes a substrate part constituting a main chuck body, a first insulating layer of a spray coating formed to the surface of the substrate part, a heater part of an electric conductor formed by applying a conductive paste to the surface of the first insulating layer, a second insulating layer of a spray coating formed to the surface of the first insulating layer so as to cover the heater part, an electrode part formed by thermal spraying to the surface of the second insulating layer and a dielectric layer of a spray coating formed to the surface of the second layer so as to cover the electrode part and lowers a volume resistivity without using an adhesive.
    Type: Application
    Filed: March 22, 2013
    Publication date: April 30, 2015
    Applicant: TOCALO CO., LTD.
    Inventors: Ryo Yamasaki, Mitsuharu Inaba, Kensuke Taguchi
  • Publication number: 20150118441
    Abstract: The present disclosure provides a multi-layer thermal protection material comprising: (i) a substrate layer; (ii) a reflection layer formed on the substrate layer; and (iii) an emission layer formed on the reflection layer and effective to convert thermal energy to photonic energy. The reflection layer comprises a porous scattering media effective to reflect photonic energy away from the substrate layer. The emission layer comprises a thermally emissive dopant incorporated into a thermal matrix material. The present disclosure also provides articles such as portions of hypersonic flight vehicles and turbine component parts that include coatings comprising the multi-layer protection material of the present disclosure. The present disclosure also provides methods of making and using the multi-layer thermal protection material and associated articles described herein.
    Type: Application
    Filed: October 25, 2013
    Publication date: April 30, 2015
    Inventors: Wen Shang, Tao DENG, Boris RUSS, Hendrik Pieter Jacobus DE BOCK, Adam RASHEED, Andrew Arthur Paul BURNS, Mohamed SAKAMI, Steven Charles ACETO, Andrey MESHKOV, Scott Michael MILLER
  • Patent number: 9011620
    Abstract: The invention is directed to effective means for joining materials having dissimilar coefficients of thermal expansion, such as advanced ceramics with metallic compounds. Moreover, the present invention relates to furnace tubes and methods of fabricating a joint between two different materials, which is compositionally graded to provide a substantially graded coefficient of thermal expansion between the joint materials.
    Type: Grant
    Filed: September 11, 2009
    Date of Patent: April 21, 2015
    Assignee: Technip Process Technology, Inc.
    Inventors: John Andrew Fernie, Martyn David Roberts, Yong Wang, Narayanan Rajesh Kavilveedu, David J. Brown
  • Patent number: 9005552
    Abstract: Provided is a new catalyst capable of removing carbon monoxide economically without adding particular reaction gas externally. Also provided are a process for producing and an apparatus using such a catalyst. Impregnation of a Ni—Al composite oxide precursor of a nonstoichiometric composition prepared by the solution-spray plasma technique with a ruthenium salt to be supported and performing reduction treatment allows CO methanation reaction to selectively proceed even in the high-temperature range in which CO2 methanation reaction and reverse water-gas-shift reaction proceed preferentially with conventional catalysts. Selective CO methanation reaction occurs reproducibly with another Ni—Al composite oxide precursor or an additive metallic species.
    Type: Grant
    Filed: October 21, 2011
    Date of Patent: April 14, 2015
    Assignee: University of Yamanashi
    Inventors: Masahiro Watanabe, Hisao Yamashita, Kazutoshi Higashiyama, Toshihiro Miyao, Aihua Chen
  • Publication number: 20150098545
    Abstract: A zirconium alloy nuclear reactor cylindrical cladding has an inner Zr substrate surface (10), an outer volume of protective material (22), and an integrated middle volume (20) of zirconium oxide, zirconium and protective material, where the protective material is applied by impaction at a velocity greater than 340 meters/second to provide the integrated middle volume (20) resulting in structural integrity for the cladding.
    Type: Application
    Filed: November 20, 2014
    Publication date: April 9, 2015
    Inventors: Jason P. Mazzoccoli, Edward J. Lahoda, Peng Xu
  • Publication number: 20150093566
    Abstract: A wear resistant coating and a method of forming a wear resistant coating on a substrate. The method includes applying a plurality of round particles to the substrate, each of the plurality of round particles including a round outer layer encapsulating a wear resistant element. The method comprises applying a wear resistant coating binder to the substrate. The method includes heating the plurality of round particles and the wear resistant coating binder.
    Type: Application
    Filed: October 1, 2014
    Publication date: April 2, 2015
    Inventor: Andrew BELL
  • Publication number: 20150086725
    Abstract: A thermal spray system and method includes a hot gas generator with nozzle accelerating heated gas towards a substrate in the form of a gas column projecting onto the substrate surface as a spot. One or more feedstock injectors proximate the nozzle exit, directed towards the gas column, are connected to a feedstock source. The hot gas stream transfers heat and momentum to the feedstock, causing the feedstock particles to impact onto a substrate to form a coating. The system further comprises one or more liquid injectors proximate the nozzle exit, directed towards the axis, and connected to a source of liquid. The system controls the flow and velocity with which the liquid is injected, permitting control of the depth of penetration of the liquid into the gas column. The method selectively prevents suboptimal feedstock particulates from adhering to the substrate and provides for the in-situ removal of suboptimal deposits.
    Type: Application
    Filed: December 4, 2014
    Publication date: March 26, 2015
    Inventor: Kent VanEvery
  • Publication number: 20150083227
    Abstract: An article includes a substrate with a coating having asperities such that an average spacing between the asperities is between about 0.01 and about 1.5 micron. An average surface roughness of the coating is up to about 2 microns, and an average porosity of the coating is in the range from about 35% to about 70%. A material to reduce surface energy is disposed on the coating. A method for making such an article and a method for decreasing fluid drag across such an article are also provided.
    Type: Application
    Filed: September 26, 2013
    Publication date: March 26, 2015
    Inventors: Rahul Anil BIDKAR, Ambarish Jayant KULKARNI, Luc Stephane LEBLANC, Vaibhav BAHADUR
  • Patent number: 8986792
    Abstract: To apply a thermal barrier coating (10), a plasma jet (5) is generated by a plasma torch in a work chamber (2) and is directed to the surface of a substrate (3) introduced into the work chamber, and a ceramic coating material is applied to the substrate surface by means of PS-PVD, wherein the coating material is injected into the plasma jet as a powder and is partly or completely vaporized there. On applying the thermal barrier coating, in a first workstep the feed rate of the injected powder is set so that a large part of the injected powder vaporizes, wherein the coating material condenses from the vapor phase on the substrate surface and forms mixed phases with the material of the substrate surface.
    Type: Grant
    Filed: February 22, 2013
    Date of Patent: March 24, 2015
    Assignees: Oerlikon Metco AG, Forschungszentrum Julich GmbH
    Inventors: Andreas Hospach, Robert Vassen, Georg Mauer, Karl-Heinz Rauwald, Detlev Stöver, Konstantin von Niessen, Malko Gindrat
  • Publication number: 20150079370
    Abstract: A method of plasma spraying an article comprises inserting the article into a vacuum chamber for a low pressure plasma spraying system. A low pressure plasma spray process is then performed by the low pressure plasma spraying system to form a first plasma resistant layer having a thickness of 20-500 microns and a porosity of over 1%. A plasma spray thin film, plasma spray chemical vapor deposition or plasma spray physical vapor deposition process is then performed by the low pressure plasma spraying system to deposit a second plasma resistant layer on the first plasma resistant layer, the second plasma resistant layer having a thickness of less than 50 microns and a porosity of less than 1%.
    Type: Application
    Filed: August 18, 2014
    Publication date: March 19, 2015
    Inventors: Jennifer Y. Sun, Yikai Chen, Biraja P. Kanungo
  • Publication number: 20150075714
    Abstract: A method for forming a plasma resistant ceramic coating on an article includes placing the article into a chamber or spray cell of a plasma spraying system. A ceramic powder is then fed into the plasma spraying system at a powder feed rate, and a plasma resistant ceramic coating is deposited onto at least one surface of the article in a plasma spray process by the plasma spray system. The plasma spray system is then used to perform an in-situ plasma flame heat treatment of the plasma resistant ceramic coating to form crust on the plasma resistant ceramic coating.
    Type: Application
    Filed: August 18, 2014
    Publication date: March 19, 2015
    Inventors: Jennifer Y. Sun, Yikai Chen, Biraja P. Kanungo
  • Publication number: 20150060025
    Abstract: Thermal spray coating methods and thermal spray coated articles are disclosed. The thermal spray coating method includes positioning a covering on a cooling channel of a component, and thermal spraying a feedstock onto the covering. The covering prohibits the feedstock from entering the cooling channel in the component and is not removed from the component. In another embodiment, the thermal spray coating method includes providing a component comprising a substrate material, providing a cooling channel on a surface of the component, positioning a covering on the cooling channel, and thermal spraying a feedstock onto the component and the covering, the feedstock comprising a bond coat material. The covering prohibits the bond coat material from entering the cooling channel. The thermal spray coated article includes a component, a cooling channel, a covering on the cooling channel, and a thermally sprayed coating on the component and the covering.
    Type: Application
    Filed: August 29, 2013
    Publication date: March 5, 2015
    Inventor: Jon Conrad SCHAEFFER
  • Patent number: 8968760
    Abstract: A method for attaching an implant to tissue is disclosed. In embodiments, a method includes applying a sprayable material to tissue, the sprayable material possessing functional groups capable of binding to tissue. The sprayable material also possesses functional groups capable of binding to an implant. In embodiments, the functional groups capable of binding to an implant include nucleotides. In such a case, the implant possesses complementary nucleotides capable of binding to the nucleotides on the sprayable material, thereby permitting hydrogen binding between the two. The implant may thus be affixed to tissue, and repositioned as necessary, prior to more permanent attachment utilizing means such as sutures, tacks, etc.
    Type: Grant
    Filed: February 24, 2012
    Date of Patent: March 3, 2015
    Assignee: Covidien LP
    Inventors: Timothy Sargeant, Jonathan Thomas
  • Patent number: 8969237
    Abstract: Disclosed are, inter alia, methods of forming coated substrates for use in catalytic converters, as well as washcoat compositions and methods suitable for using in preparation of the coated substrates, and the coated substrates formed thereby. The catalytic material is prepared by a plasma-based method, yielding catalytic material with a lower tendency to migrate on support at high temperatures, and thus less prone to catalyst aging after prolonged use. Also disclosed are catalytic converters using the coated substrates, which have favorable properties as compared to catalytic converters using catalysts deposited on substrates using solution chemistry. Also disclosed are exhaust treatment systems, and vehicles, such as diesel vehicles, particularly light-duty diesel vehicles, using catalytic converters and exhaust treatment systems using the coated substrates.
    Type: Grant
    Filed: January 27, 2014
    Date of Patent: March 3, 2015
    Assignee: SDCmaterials, Inc.
    Inventors: Qinghua Yin, Xiwang Qi, Maximilian A. Biberger, Jayashir Sarkar
  • Patent number: 8961867
    Abstract: Refractory metal powders are dehydrided in a device which includes a preheat chamber for retaining the metal powder fully heated in a hot zone to allow diffusion of hydrogen out of the powder. The powder is cooled in a cooling chamber for a residence time sufficiently short to prevent re-absorption of the hydrogen by the powder. The powder is consolidated by impact on a substrate at the exit of the cooling chamber to build a deposit in solid dense form on the substrate.
    Type: Grant
    Filed: May 23, 2013
    Date of Patent: February 24, 2015
    Assignee: H.C. Starck Inc.
    Inventors: Steven A. Miller, Mark Gaydos, Leonid N. Shekhter, Gokce Gulsoy
  • Patent number: 8941025
    Abstract: Plume shield shroud (10) for a plasma gun (30) includes a substantially tubular member (14) comprising an axial length, a plume entry end (11), and a plume exit end (13). The shroud (10) is adapted to be mounted to a plasma gun (30). A method of protecting, confining or shielding of a gas plume of a plasma gun (30) includes mounting (20) a gas plume shroud (10) on the plasma gun (30) such that the shroud (10) is sized and configured to substantially surround at least a portion of the gas plume.
    Type: Grant
    Filed: January 25, 2011
    Date of Patent: January 27, 2015
    Assignee: Oerlikon Metco (US) Inc.
    Inventors: Richard McCullough, Mark F. Spaulding, Robert F. Savill, Jr., Ronald J. Molz
  • Patent number: 8936826
    Abstract: A method of coating a stent involves modifying a spray coating parameter until a target mass per coating layer is achieved. A method for coating involves spraying a batch of stents according to spraying parameters that were previously determined to provide a target mass per coating layer.
    Type: Grant
    Filed: August 22, 2011
    Date of Patent: January 20, 2015
    Assignee: Abbott Cardiovascular Systems Inc.
    Inventors: Kevin Jow, Daniel A. Castro
  • Publication number: 20150017430
    Abstract: The invention relates to a component (1) having a coating (3) that is metallurgically bonded on as well as thermally sprayed on and re-melted. In order to prevent wear phenomena from continuing to occur when force impacts occur in the component (1) and further surface stress occurs, the invention provides that the coating (3) is provided with a thermal spray layer (4).
    Type: Application
    Filed: March 11, 2013
    Publication date: January 15, 2015
    Applicant: Thermico GmbH & Co. KG
    Inventor: Goetz Matthaeus
  • Publication number: 20150017339
    Abstract: Substrate structure comprising a substrate (6) and a plasma grown layer (6a). The surface of the resulting substrate structure (7) is characterized by interrelated scaling components. The scaling components comprise a roughness exponent ?, a growth exponent ? and a dynamic exponent z, wherein the growth exponent ? has a value of less than 0.2 and the dynamic exponent z has a value of more than 6. Also disclosed is a method to provide such a substrate structure.
    Type: Application
    Filed: June 9, 2014
    Publication date: January 15, 2015
    Inventors: Hindrik Willem DE VRIES, Mauritius Cornelius Maria VAN DE SANDEN