Silicon Containing Coating Patents (Class 427/452)
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Patent number: 7056596Abstract: A method for coating a surface of a track component with a coating containing aluminum by means of an arc spraying process. In order to form a coating that exhibits a high resistance to sliding and abrasive wear, aluminum and silicon are applied to the surface in a ratio of 3:2 ?Al:Si?4:1 by an arc spraying process.Type: GrantFiled: June 26, 2003Date of Patent: June 6, 2006Assignees: BWG GmbH & Co. KG, Vae GmbHInventors: Walter Kunitz, Joachim Heilscher, Stefan Schmedders
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Patent number: 7045172Abstract: This invention provides a unique gas shield or shroud surrounding the effluent of a thermal spray device that effectively can extend the working distance or standoff between the thermal spray device and the surface being coated. This invention provides a method of spraying materials, including ceramic materials and reactive materials, at a long standoff and a method of controlling the temperature of the effluent being deposited using heated gas shield.Type: GrantFiled: July 31, 2003Date of Patent: May 16, 2006Assignee: Praxair S.T. Technology, Inc.Inventors: Thomas A. Taylor, John E. Jackson
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Patent number: 7026009Abstract: A component for a substrate processing chamber comprises a structure having a textured coating with surface grains. The component is evaluated by directing a beam of electrons onto the textured coating of the component to cause at least some of the electrons to be backscattered. The backscattered electrons are detected and a signal image is generated. The component is selected when the signal image exhibits surface grains sized from about 0.1 to about 5 micron. In one version, the component is also selected when the grains are substantially flower shaped.Type: GrantFiled: March 27, 2002Date of Patent: April 11, 2006Assignee: Applied Materials, Inc.Inventors: Shyh-Nung Lin, Mark D. Menzie, Nimoal Sun
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Patent number: 6994800Abstract: Volatile liquid precursors are provided for use in the formation of alkali metal-containing materials. The compound includes an alkali metal and an amide ligand and is a liquid at a temperature of less than about 70° C.Type: GrantFiled: April 28, 2000Date of Patent: February 7, 2006Assignee: President and Fellows of Harvard CollegeInventors: Roy G. Gordon, Randy N. R. Broomhall-Dillard
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Patent number: 6916541Abstract: The present invention relates to a substrate for attachment of biomolecules. The substrate is coated with a multiamino organosilane. If desired, the substrate can be further modified prior to coating with a multiamino organosilane. Optional surface modifications include coating the substrate with SiO2 or leaching with acid to form a SiO2 rich layer. DNA, nucleic acids, or any bimolecules can be attached to the coated substrates of the invention. Although a variety of substrates are contemplated, the preferred substrate is a low self-fluorescent glass.Type: GrantFiled: September 7, 2001Date of Patent: July 12, 2005Assignee: Penn State Research FoundationInventors: Carlo G. Pantano, Ezz Metwalli, Samuel Conzone, Dan Haines
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Patent number: 6897169Abstract: A fire-resistant heat insulating material excellent in resistance to heat, resistance to slag, resistance to molten iron, resistance to wear, and resistance to mechanical impulse is provided. A highly endurable heat insulating material characterized by being provided on the surface of a layer of inorganic heat insulating fibers through the medium of a coating film of surface hardening material with a flame sprayed film of a fire-resistant ceramic substance.Type: GrantFiled: May 3, 2001Date of Patent: May 24, 2005Assignee: Nippon Steel CorporationInventors: Taijiro Matsui, Hiroshi Imagawa, Tsuneo Kayama, Shinji Aso
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Patent number: 6896933Abstract: A method of maintaining a non-obstructed interior opening in a kinetic spray nozzle is disclosed. The method includes the steps of providing a mixture of particles including first particle population and a second particle population; entraining the mixture of particles into a flow of a gas at a temperature below the melt temperature of the particle populations; and directing the mixture of particles entrained in the flow of gas through a supersonic nozzle to accelerate the first particle population to a velocity sufficient to result in adherence of the first particle population on a substrate positioned opposite the nozzle. The operating conditions of the kinetic spray system are selected such that the second particle population is not accelerated to a velocity sufficient to result in adherence when it impacts the substrate.Type: GrantFiled: April 5, 2002Date of Patent: May 24, 2005Assignee: Delphi Technologies, Inc.Inventors: Thomas Hubert Van Steenkiste, John R. Smith, Daniel William Gorkiewicz, Alaa A. Elmoursi, Bryan A. Gillispie, Nilesh B. Patel
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Patent number: 6884470Abstract: A method for applying a highly porous alumina material that is useful in the hot section of a jet aircraft engine. In order to apply the porous alumina, an aluminum-based metal/alumina material known in the art is first placed onto an aircraft engine component substrate. The aluminum-based metal is then dissolved using a solution that will not affect the alumina or the underlying substrate. The alumina is then washed with deionized water and dried. The aircraft engine component may be first masked by applying a non-porous metal oxide material to the component or by oxidizing the surface of the component. The resulting alumina has a porosity in the range of about 20% to about 45%. The alumina has globular interconnected surface features in the range of about 0.5 ?m to about 20 ?m.Type: GrantFiled: October 3, 2002Date of Patent: April 26, 2005Assignee: General Electric CompanyInventor: Mark D. Gorman
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Patent number: 6884471Abstract: The invention discloses a method of producing a light-scattering layer on a transparent body, in particular consisting of glass or a glass ceramic. The light-scattering layer is produced by thermal spraying a material such as aluminum oxide, titanium oxide etc. onto a surface of the preheated body with a maximum layer thickness of 100 micrometers. The method is particularly suited for preparing light-scattering layers on glass ceramic cooktops.Type: GrantFiled: November 6, 2003Date of Patent: April 26, 2005Assignee: Schott AGInventors: Bernd Schultheis, Cora Krause, Karsten Wermbter
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Patent number: 6866897Abstract: A method for manufacturing an article for use in a high-temperature environment, and an article for use in such an environment, are presented. The method comprises providing a substrate; selecting a desired vertical crack density for a protective coating to be deposited on the substrate; providing a powder, wherein the powder has a size range selected to provide a coating having the desired vertical crack density; and applying a thermal-sprayed coating to the substrate, the coating having the desired vertical crack density, wherein the powder is used as a raw material for the coating.Type: GrantFiled: September 30, 2002Date of Patent: March 15, 2005Assignee: General Electric CompanyInventors: Hongyu Wang, David Joseph Mitchell, Yuk-Chiu Lau, Arnold Thomas Henry
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Patent number: 6861101Abstract: A method of operation of a plasma torch. A cold high pressure carrier gas containing a powder material is injected into a cold main high pressure gas flow and then this combined flow is directed coaxially around a plasma exiting from an operating plasma generator and converging into the hot plasma effluent, mixing with the effluent to form a gas stream with a net temperature, based on the enthalpy of the plasma stream and the temperature and volume of the cold high pressure converging gas, such that the powdered material will not melt. The combined flow with entrained is directed through a supersonic nozzle accelerating the flow to supersonic velocites sufficient that the particles striking the workpiece achieve kinetic energy transformation into elastic deformation of the particles as they impact the workpiece forming a cohesive coating.Type: GrantFiled: December 19, 2002Date of Patent: March 1, 2005Assignee: Flame Spray Industries, Inc.Inventors: Keith A Kowalsky, Daniel R Marantz
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Patent number: 6846742Abstract: Embodiments of the present invention include a method of depositing an improved seasoning film. In one embodiment the method includes, prior to performing a substrate processing operation, forming a layer of silicon over an interior surface of the substrate processing chamber as opposed to a layer of silicon oxide. In certain embodiments, the layer of silicon comprises at least 70% atomic silicon, is deposited from a high density silane (SinH2n+2) process gas and/or is deposited from a plasma having a density of at least 1×1011 ions/cm3.Type: GrantFiled: June 16, 2003Date of Patent: January 25, 2005Assignee: Applied Materials, Inc.Inventor: Kent Rossman
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Patent number: 6841200Abstract: A method and apparatus for transferring a substrate between a first environment having a first pressure and a second environment having a vacuum pressure is provided. In one embodiment, the apparatus comprises a chamber body having a first port disposed in a first wall and a second port disposed in a second wall that seals the chamber from the first and second environments. A cooling plate, a first substrate holder and a second substrate holder are disposed within the chamber body. The cooling plate is disposed at the bottom of the chamber body. The first port and the second port are sequentially opened and the pressure within the load lock regulated to allow substrate to pass through the load lock. A window is disposed in the top of the chamber body that allows a metrology device to view the chamber volume.Type: GrantFiled: March 17, 2003Date of Patent: January 11, 2005Assignee: Applied Materials, Inc.Inventors: Joseph Arthur Kraus, James David Strassner
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Patent number: 6833165Abstract: The present invention relates to a method including thermal spraying a chromium nitride or a chromium carbide and chromium silicide coating material on to an article. The coating material may be in a powder form before thermal spraying. In one aspect, the thermal spraying includes melting the coating material, propelling the molten coating material toward the article to be coated, and coating the article with the molten coating material. In another aspect, the coated article is one or more piston rings.Type: GrantFiled: September 26, 2002Date of Patent: December 21, 2004Assignee: Dana CorporationInventors: Thomas J. Smith, Thomas Stong, Peter Einberger
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Patent number: 6830781Abstract: In a known method for producing an SiO2 blank, SiO2 particles are formed in a burner flame assigned to a deposition burner and are deposited under the effect of an electrical field on a deposition surface of a carrier rotating about its longitudinal axis, said at least one deposition burner being reciprocated in a predetermined sequence of movement along the developing blank between turn-around points. Starting from said method, in order to obtain blanks of a predetermined, in particular axially homogeneous, density and mass distribution, it is suggested according to the invention that the geometrical shape of the burner flame should be varied by the electrical field in dependence upon the position of the deposition burner during the sequence of movement.Type: GrantFiled: November 7, 2001Date of Patent: December 14, 2004Assignee: Heraeus Quarzglas GmbH & Co. KGInventor: Heinz Fabian
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Patent number: 6827826Abstract: Physical vapor deposition processes provide optical materials with controlled and uniform refractive index that meet the requirements for active and passive planar optical devices. All processes use radio frequency (RF) sputtering with a wide area target, larger in area than the substrate on which material is deposited, and uniform plasma conditions which provide uniform target erosion. In addition, a second RF frequency can be applied to the sputtering target and RF power can be applied to the substrate producing substrate bias. Multiple approaches for controlling refractive index are provided. The present RF sputtering methods for material deposition and refractive index control are combined with processes commonly used in semiconductor fabrication to produce planar optical devices such surface ridge devices, buried ridge devices and buried trench devices. A method for forming composite wide area targets from multiple tiles is also provided.Type: GrantFiled: November 4, 2002Date of Patent: December 7, 2004Assignee: Symmorphix, Inc.Inventors: Richard E. Demaray, Kai-An Wang, Ravi B. Mullapudi, Douglas P. Stadtler, Hongmei Zhang, Rajiv Pethe
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Patent number: 6815003Abstract: A method for fabricating an electrode for lithium secondary battery formed by depositing a thin film composed of active material capable of lithium storage and release, on a metallic foil to be used as a current collector, in which the surface of the metallic foil is roughened through wet-etching and then the thin film is deposited on the roughened surface.Type: GrantFiled: November 29, 2001Date of Patent: November 9, 2004Assignee: Sanyo Electric Co., Ltd.Inventors: Hiromasa Yagi, Koji Endo, Hisaki Tarui, Hiroshi Okano, Shingo Nakano
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Patent number: 6787194Abstract: A pulsed detonation gun comprises a small-diameter detonation tube, an igniter, and an outlet for discharging detonation products containing a coating material. A detonable or reactive mixture containing a coating precursor is formed in the detonation tube, and the detonable or reactive mixture is ignited to produce detonation or reaction products containing the coating precursor or a coating material formed in situ during a detonation process or a deflagration process. The coating material is discharged through the outlet and is contacted with the substrate to produce a coating. The device is particularly useful for coating the inside surfaces of small-diameter tubes and a variety of other difficult-to-reach substrate surfaces.Type: GrantFiled: April 17, 2002Date of Patent: September 7, 2004Assignee: Science Applications International CorporationInventor: Shmuel Eidelman
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Patent number: 6787195Abstract: A process of depositing a coating system suitable for use as an environmental barrier coating on various substrate materials, particularly those containing silicon and intended for high temperature applications such as the hostile thermal environment of a gas turbine engine. The process comprises depositing a first coating layer containing mullite, and preferably a second coating layer of an alkaline earth aluminosilicate, such as barium-strontium-aluminosilicate (BSAS), by thermal spraying while maintaining the substrate at a temperature of 800° C. or less, preferably 500° C. or less, by which a substantially crack-free coating system is produced with desirable mechanical integrity.Type: GrantFiled: February 3, 2003Date of Patent: September 7, 2004Assignee: General Electric CompanyInventors: Hongyu Wang, Yuk-Chiu Lau, Irene Spitsberg, Arnold T. Henry
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Patent number: 6760396Abstract: The method of protectively coating metallic uranium which comprises dipping the metallic uranium in a molten alloy comprising about 20-75% of copper and about 80-25% of tin, dipping the coated uranium promptly into molten tin, withdrawing it from the molten tin and removing excess molten metal, thereupon dipping it into a molten metal bath comprising aluminum until it is coated with this metal, then promptly withdrawing it from the bath.Type: GrantFiled: February 4, 1946Date of Patent: July 6, 2004Assignee: The United States of America as represented by the United States Department of EnergyInventors: Ernest R. Boller, Lowell D. Eubank
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Patent number: 6749900Abstract: A coating material is deposited on a substrate by vacuum or low-pressure pulsed detonation coating. A detonation chamber receives a detonable mixture containing a coating precursor. The detonable mixture is ignited to produce detonation products laden with the coating precursor. The detonation products are accelerated in a low-pressure or vacuum chamber and discharged through a nozzle into contact with a substrate situated in low pressure to produce a high quality coating.Type: GrantFiled: May 16, 2003Date of Patent: June 15, 2004Assignee: Science Applications International CorporationInventor: Shmuel Eidelman
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Patent number: 6743369Abstract: A method of manufacturing an electrode for a secondary battery by depositing a thin film composed of active material on a current collector in which a surface-treated layer such as an antirust-treated layer is formed, including the steps of: removing at least part of the surface-treated layer by etching the surface of the current collector with an ion beam or plasma in order to improve the diffusion of the current collector material into the active material thin film; and depositing the thin film on the surface of the current collector subjected to the etching step.Type: GrantFiled: December 17, 2001Date of Patent: June 1, 2004Assignee: Sanyo Electric Co., Ltd.Inventors: Daizo Jito, Hisaki Tarui
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Patent number: 6740364Abstract: A process for depositing a ceramic coating system for Si-containing materials, particularly those for articles exposed to high temperatures. The process is particularly applicable to depositing a compositionally-graded coating system comprising multiple ceramic layers with differing compositions, including a dense, strain-tolerant, vertically-cracked YSZ-containing ceramic layer deposited on a ceramic layer having a composition that is a mixture of YSZ and either mullite or BSAS. The process entails depositing the YSZ-containing ceramic layer using a plasma spraying technique while maintaining the substrate at a temperature so as not to form horizontal cracks in the coating system, but still maintain the dense vertically-cracked structure of the YSZ-containing ceramic layer for strain tolerance.Type: GrantFiled: May 30, 2002Date of Patent: May 25, 2004Assignee: General Electric CompanyInventors: Yuk-Chiu Lau, Hongyu Wang, David Joseph Mitchell
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Patent number: 6737121Abstract: According to an exemplary embodiment of the invention, a method of forming a plurality of layers on an article comprises steps of generating a plasma by forming an arc between a cathode and an anode; injecting a first material comprising an organic compound into the plasma to deposit a first layer on the article; injecting a second material comprising an organometallic material into the plasma to form a second layer on the first layer; and injecting a third material comprising a silicon containing organic compound into the plasma to deposit a third layer on the second layer. The invention also relates to an article of manufacture comprising a substrate; an interlayer disposed on the substrate; a second layer disposed on the interlayer, the second layer comprising an inorganic ultraviolet absorbing material; and a third layer disposed on the second layer, the third layer comprising an abrasion resistant material.Type: GrantFiled: January 16, 2002Date of Patent: May 18, 2004Assignee: General Electric CompanyInventors: Barry Lee-Mean Yang, Charles Dominic Iacovangelo
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Patent number: 6733891Abstract: Rolls include a core and a glass outer coating on the core. The glass can be electrically charged and discharged. The outer coatings have smooth finishes and controlled electrical properties. The outer coatings can also provide selected mechanical, chemical and thermal properties. The rolls can be used in various applications in which controlled electrical properties are desired. For example, the rolls can be used as charge donor rolls in electrostatographic imaging apparatus.Type: GrantFiled: May 31, 2000Date of Patent: May 11, 2004Assignee: Xerox CorporationInventors: Christopher D. Blair, Timothy R. Jaskowiak
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Patent number: 6730616Abstract: A versatile system for forming diffusion barriers in semiconductor processing that simplifies device processing, utilizing existing production compounds and materials while resulting in uniform and proper device structuring, is disclosed, providing a system using a reactive plasma to selectively form diffusion barriers and provide selective oxidation.Type: GrantFiled: September 24, 2002Date of Patent: May 4, 2004Assignee: Texas Instruments IncorporatedInventor: Scott R. Summerfelt
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Patent number: 6727005Abstract: Manufacturing low density components of high surface strength having a polymer or metal matrix substrate and ceramics and/or metal-ceramics coating, wherein the low density substrate to be coated is subjected to: optionally, machining the surface in order to generate residual compressive stress in the outer layers; optionally, thermal stabilizing at a temperature lower than 350° C.; depositing onto the outer surface, with hot spraying techniques at a temperature ranging from 70 to 350° C., of a coating layer in ceramics and/or metal-ceramics material of a surface strength higher than that of the component to be coated, the surface of the coating layer being optionally subjected to a finishing treatment. The disclosure also relates to the product thus obtained.Type: GrantFiled: October 22, 2002Date of Patent: April 27, 2004Assignee: Centro Sviluppo Materiali S.p.A.Inventors: Pietro Gimondo, Carlo Costa
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Patent number: 6723387Abstract: A thermal spray method for the fabrication of ceramic/metal and ceramic/ceramic hardcoating for wear applications. The method makes use of feedstock powder, composed of micron-scale aggregates of hard phase material particles that are either mixed or coated with a readily fusible nano-scale binder phase material. Thus, during thermal spraying, the nanostructured material undergoes rapid melting while the aggregated material is heated but not necessarily melted. A dense coating is formed when the molten nano-material fills the available pore spaces between the heated and softened aggregates, providing a strong and tough matrix for the consolidated material. Optimal wear properties are achieved when the volume fraction of aggregated particles is high, typically in the range of 0.5-0.9. Aggregated material may be composed of one, two or more particles of difference sizes and/or compositions, with particle size distribution that gives high packing density for the hard phase.Type: GrantFiled: September 19, 2002Date of Patent: April 20, 2004Assignee: Rutgers UniversityInventors: Bernard H. Kear, Ganesh Skandan
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Patent number: 6692844Abstract: The life of ceramic SPF dies can be enhanced significantly by plasma spray application of a cordierite glaze on the forming surface. The preferred glaze has a coefficient of thermal expansion close to or matching with the ceramic of the die, and, typically, is a 2•2•5 MAS system including 2-10 mol % TiO2 (or above 8 wt %).Type: GrantFiled: August 28, 2001Date of Patent: February 17, 2004Assignee: The Boeing CompanyInventors: Daniel G. Sanders, Martin A. Peterson, David C. Van Aken, D. Trent Weaver, F. Scott Miller, Jeffrey D. Smith
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Patent number: 6682780Abstract: A method for protecting low-carbon steel and stainless steel from coking and corrosion at elevated temperatures in corrosive environments, such as during ethylene production by pyrolysis of hydrocarbons or the reduction of oxide ores, by coating the stainless steel with a coating of MCrAlXSiT in which M is nickel, cobalt, iron or a mixture thereof, X is yttrium, hafnium, zirconium, lanthanum, scandium or combination thereof, and T is tantalum, titanium, platinum, palladium, rhenium, molybdenum, tungsten, niobium, boron or combination thereof. A blended powder composition to produce a desired MCrAlXSiT surface alloy may be applied to the substrate. The overlay coating and stainless steel substrate preferably are heat-treated at about 1000 to 1200° C. for about 10 minutes or longer effective to metallurgically bond the overlay coating to the substrate and to form a multiphased microstructure.Type: GrantFiled: May 22, 2002Date of Patent: January 27, 2004Assignee: Bodycote Metallurgical Coatings LimitedInventors: Konstantin K. Tzatzov, Alexander S. Gorodetsky, Andrew Wysiekierski, Gary Anthony Fisher
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Patent number: 6631628Abstract: Natural or synthetic silica is deposited on a preform set into rotation in front of a plasma torch which moves back and forth substantially parallel to a longitudinal direction of the preform, a first feed duct feeds the plasma with grains of natural or synthetic silica while a second feed duct feeds the plasma with a fluorine or chlorine compound, preferably a fluorine compound, mixed with a carrier gas. Any sodium or lithium contained in the grains of natural or synthetic silica react with the fluorine or chlorine of the fluorine or chlorine compound, thereby making it possible to improve the optical quality of fibers drawn from a preform built up with natural or synthetic silica, and to do so at reduced cost.Type: GrantFiled: September 20, 2002Date of Patent: October 14, 2003Assignee: AlcatelInventors: Alain Drouart, Benoît Gouez, Yves Lumineau, Pierre Ripoche, Jean-Forent Campion
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Patent number: 6630200Abstract: A method of forming an article. The method comprises forming a silicon-based substrate that is oxidizable by reaction with an oxidant to form at least one gaseous product and applying an intermediate layer/coating onto the substrate, wherein the intermediate layer/coating is oxidizable to a nongaseous product by reaction with the oxidant in preference to reaction of the silicon-containing substrate with the oxidant.Type: GrantFiled: May 1, 2001Date of Patent: October 7, 2003Assignee: General Electric CompanyInventors: Hongyu Wang, Krishan Lal Luthra
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Patent number: 6610370Abstract: An article includes a silicon-containing substrate and a modified mullite coating. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating. The article can further comprise a thermal barrier coating applied to the modified mullite coating. The modified mullite coating functions as a bond coating between the external environmental/thermal barrier coating and the silicon-containing substrate. In a method of forming an article, a silicon-containing substrate is formed and a modified mullite coating is applied. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating.Type: GrantFiled: September 3, 2002Date of Patent: August 26, 2003Assignee: General Electric CompanyInventors: Hongyu Wang, Kang Neung Lee
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Patent number: 6607782Abstract: Methods for coating a substrate and methods of shaping a workpiece comprise formation and use, respectively, of a surface or substrate comprising a first phase selected from nitrides, carbides. carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, and a second phase selected from nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, wherein said second phase comprises a multiplicity of discrete portions positioned into the first phase, with these multiplicity of portions comprising a continuous second phase, and made thereof, coating and articles, especially machining, cutting and shaping tools, wearparts, and methods of making and using the composition, coating and articles.Type: GrantFiled: June 29, 2000Date of Patent: August 19, 2003Assignees: Board of Trustees of the University of Arkansas, Valenite, Inc.Inventors: Ajay P. Malshe, Sharad N. Yedave, William D. Brown, William C. Russell, Deepak G. Bhat
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Patent number: 6583071Abstract: A process for forming a extremely low dielectric constant film over a substrate. The process includes coating a substrate with a solution comprising a soluble source of silicon oxide, water, a solvent, a surfactant and a catalyst using an ultrasonic spray nozzle. The coated substrate is then subsequently treated to harden the solution into an extremely low dielectric constant film.Type: GrantFiled: October 18, 2000Date of Patent: June 24, 2003Assignee: Applied Materials Inc.Inventors: Timothy Weidman, Yunfeng Lu, Michael P Nault, Michael Barnes, Farhad Moghadam
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Patent number: 6578381Abstract: The oxides-enclosed fine glass particles are arranged such that two or more pieces of at least two kinds of enclosing particles, which comprise oxides, double oxides, or salts of oxyacids, or double oxides or double salts thereof, are enclosed in each of the fine glass particles. The fine particles can be easily manufactured by mixing a powder material of glass with a powder material of oxides which comprise oxides, double oxides, or salts of oxyacids, or double oxides or double salts thereof that are not made to glass; converting the thus obtained mixture of the materials into a mixture in a vapor-state by supplying the thermal plasma thereto; and quickly cooling the mixture in the vapor-state. Highly-scattered fine particles of oxides can be easily obtained from the fine particles, and thus a plurality of kinds of fine particles of oxides can be evenly and uniformly mixed in a small amount with a mother material without being unevenly scattered.Type: GrantFiled: December 20, 2001Date of Patent: June 17, 2003Assignees: Nisshin Seifun Group Inc., Nisshin Engineering Inc.Inventors: Keiichi Nishimura, Takashi Fujii, Kazuhiro Yubuta, Sadao Shinozaki
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Nanostructured feeds for thermal spray systems, method of manufacture, and coatings formed therefrom
Patent number: 6579573Abstract: This invention relates to methods whereby nanoparticle liquid suspensions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. Ultrasound is used for disintegration of the as-synthesized particle agglomerates, nanoparticle dispersion in liquid media, and liquid precursor atomization.Type: GrantFiled: May 20, 1999Date of Patent: June 17, 2003Assignees: The University of Connecticut, Rutgers The State University of New JerseyInventors: Peter R. Strutt, Bernard H. Kear, Ross F. Boland -
NANOSTRUCTURED FEEDS FOR THERMAL SPRAY SYSTEMS, METHOD OF MANUFACTURE, AND COATINGS FORMED THEREFROM
Publication number: 20030077398Abstract: This invention relates to methods whereby nanoparticle liquid suspensions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. Ultrasound is used for disintegration of the as-synthesized particle agglomerates, nanoparticle dispersion in liquid media, and liquid precursor atomization.Type: ApplicationFiled: May 20, 1999Publication date: April 24, 2003Inventors: PETER R. STRUTT, BERNARD H. KEAR, ROSS F. BOLAND -
Patent number: 6551718Abstract: Disclosed is a metal sulphide coating composition of the formula MXSiVRYSZFW where M is one or more metals selected from: Mo, Ti, W, Nb, Ta, Zr, and Hf; Si is silicon; R is one or more elements selected from: C, B, Al, V, Cr, Fe, Co, Ni, Sm, Au, Cu, Zn, Sn, Pb, N, H, and O; S is sulphur; F is fluorine; X is 0.2 to 1.5; V is 0.02 to 3; Y is 0 to 4; Z is 0.2 to 6; and W is 0.01 to 6, and in which X, Y, Z, V, and W are given in amounts by atomic ratio. The compositions show good non-stick properties, low hydrophilia, and high stability.Type: GrantFiled: June 11, 1999Date of Patent: April 22, 2003Assignee: Gencoa Ltd.Inventor: Victor Bellido-Gonzalez
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Patent number: 6544597Abstract: A mixed powder thermal spraying method includes forming a mixed thermal spraying film comprising two kinds of materials having different melting points wherein powder-feeding points are provided for each material; and each powder-feeding port is controlled respectively to externally feed each material, and wherein the thermal powder spraying method is bore thermal spraying carried out with a bent plasma jet.Type: GrantFiled: June 19, 2001Date of Patent: April 8, 2003Assignee: Suzuki Motor CorporationInventors: Tadashi Takahashi, Seiya Kunioka, Kenji Miyai
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Publication number: 20030019245Abstract: Natural or synthetic silica is deposited on a preform set into rotation in front of a plasma torch which moves back and forth substantially parallel to a longitudinal direction of the preform, a first feed duct feeds the plasma with grains of natural or synthetic silica while a second feed duct feeds the plasma with a fluorine or chlorine compound, preferably a fluorine compound, mixed with a carrier gas. Any sodium or lithium contained in the grains of natural or synthetic silica react with the fluorine or chlorine of the fluorine or chlorine compound, thereby making it possible to improve the optical quality of fibers drawn from a preform built up with natural or synthetic silica, and to do so at reduced cost.Type: ApplicationFiled: September 20, 2002Publication date: January 30, 2003Applicant: ALCATEL ALSTHOM COMPAGNIE GENERALE D'ELECTRICITEInventors: Alain Drouart, Benoit Gouez, Yves Lumineau, Pierre Ripoche, Jean-Forent Campion
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Patent number: 6497922Abstract: Corrosion-resistant, oxidation-resistant, and/or wear-resistant coatings are made of ternary ceramic compounds of the general formula (I): M2X1Z1 (I) wherein M is at least one transition metal, X is an element selected from the group consisting of Si, Al, Ge, Pb, Sn, Ga, P, S, In, As, Tl and Cd, and Z is a non-metal selected from the group consisting of carbon and nitrogen; and/or compounds of the general formula (II): M3X1Z2 (II) wherein M is at least one transition metal, X is at least one of Al, Ge, and Si, and Z is at least one of carbon and nitrogen. Such coatings may be applied by a thermal spraying process.Type: GrantFiled: May 14, 2001Date of Patent: December 24, 2002Assignee: Drexel UniversityInventors: Richard Knight, Michel W. Barsoum
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Patent number: 6488992Abstract: Elastomeric seals, including O-rings, may have chemically resistant thin films applied by the technique of plasma polymerization to the surface of the elastomer, enhancing wear resistance and environmental resistance without changing the physical properties of the elastomer. The films may be a silane polymer applied by plasma deposition in a radio frequency/microwave dual power source reactor.Type: GrantFiled: August 18, 1999Date of Patent: December 3, 2002Assignee: University of CincinnatiInventors: F. James Boerio, Alan M. Dickey, R. Giles Dillingham, Kristy J. Johnson, David A. Penning
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Patent number: 6485791Abstract: Improved adhesion of thermal barrier coatings to nonmetallic substrates using a dense layer of ceramic on an underlying nonmetallic substrate that includes at least one oxidizable component. The improved adhesion occurs because the application of the dense ceramic layer forms a diffusion barrier for oxygen. This diffusion barrier prevents the oxidizable component of the substrate from decomposing. The present invention applies ceramic by a process that deposits a relatively thick and dense ceramic layer on the underlying substrate. The formation of the dense layer of ceramic avoids the problem of void formation associated with ceramic formation by most prior art thermal decomposition processes. The formation of voids has been associated with premature spalling of thermal barrier layers and other protective layers applied to substrates.Type: GrantFiled: April 6, 2000Date of Patent: November 26, 2002Inventor: Bangalore A. Nagaraj
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Patent number: 6477864Abstract: Natural or synthetic silica is deposited on a preform set into rotation in front of a plasma torch which moves back and forth substantially parallel to a longitudinal direction of the preform, a first feed duct feeds the plasma with grains of natural or synthetic silica while a second feed duct feeds the plasma with a fluorine or chlorine compound, preferably a fluorine compound, mixed with a carrier gas. Any sodium or lithium contained in the grains of natural or synthetic silica react with the fluorine or chlorine of the fluorine or chlorine compound, thereby making it possible to improve the optical quality of fibers drawn from a preform built up with natural or synthetic silica, and to do so at reduced cost.Type: GrantFiled: March 5, 1998Date of Patent: November 12, 2002Assignee: AlcatelInventors: Alain Drouart, Benoît Gouez, Yves Lumineau, Pierre Ripoche, Jean-Florent Campion
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Patent number: 6463760Abstract: The wet film thickness during spraying of the coating composition onto the substrate is preferably adjusted such that it is greater by a factor of at least 8 than the target dry film thickness.Type: GrantFiled: February 23, 2001Date of Patent: October 15, 2002Assignee: Institut für Neue Materialien gemeinnützige GmbHInventors: Claudia Fink-Straube, Axel Kalleder, Thomas Koch, Martin Mennig, Helmut Schmidt
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Patent number: 6460374Abstract: A glass-impregnated, fiber-reinforced ceramic comprises a ceramic matrix having open voids, inorganic fibers embedded in the ceramic matrix in a regular or irregular orientation, and a glass matrix filling up the open voids in the ceramic matrix. The glass-impregnated, fiber-reinforced ceramic is manufactured by a manufacturing method comprising the steps of forming a fiber-reinforced ceramic comprising the ceramic matrix having open voids, and inorganic fibers embedded in the ceramic matrix, impregnating the fiber-reinforced ceramic with a glass precursor solution containing a glass precursor to stop up the open voids of the ceramic matrix with the glass precursor solution, and subjecting the fiber-reinforced ceramic impregnated with the solution to a heat treatment.Type: GrantFiled: November 30, 1999Date of Patent: October 8, 2002Assignees: Kawasaki Jukogyo Kabushiki Kaisha, Ube Industries, Ltd.Inventors: Akihito Sakai, Jun Gotoh, Keiichi Tsugeki, Masaki Shibuya, Yasuhiro Shioji
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Patent number: 6447848Abstract: Thin films or coatings having a thickness of about 100 nanometers or larger are made of nanostructured particles which have a particle size less than 100 nm (i.e. 0.1 micron) by thermally spraying a solution of a liquid coating precursor feedstock onto a substrate to form the film or coating. By thermal spraying with different precursor feedstock solutions, coatings can be made with more than one layer. Also, by varying the composition of the precursor feedstock during spraying, a fine composition gradient coating can be formed which is made up of the same small nanoparticle size particles of less than, 100 nm. Many combinations of materials can be co-deposited and by applying an external energy source either during the coating process or during post deposition, the resulting coating can be modified.Type: GrantFiled: June 30, 1998Date of Patent: September 10, 2002Assignee: The United States of America as represented by the Secretary of the NavyInventors: Gan-Moog Chow, Lynn K. Kurihara, T. Danny Xiao, Peter R. Strutt, Christopher W. Strock, Raymond A. Zatorski
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Publication number: 20020119340Abstract: An environmentally resistant coating comprising silicon, titanium, chromium, and a balance of niobium and molybdenum for turbine components formed from molybdenum silicide-based composites. The turbine component may further include a thermal barrier coating disposed upon an outer surface of the environmentally resistant coating comprising zirconia, stabilized zirconia, zircon, mullite, and combinations thereof. The molybdenum silicide-based composite turbine component coated with the environmentally resistant coating and thermal barrier coating is resistant to oxidation at temperatures in the range from about 2000° F. to about 2600° F. and to pesting at temperatures in the range from about 1000° F. to about 1800° F.Type: ApplicationFiled: February 26, 2001Publication date: August 29, 2002Applicant: General Electric CompanyInventors: Ji-Cheng Zhao, Bernard Patrick Bewlay, Melvin Robert Jackson
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Patent number: 6436480Abstract: To prepare a thermally sprayed composite material, a precomposited powder is first prepared and then thermally sprayed at an ambient pressure of no less than about 0.75 atmosphere in an oxidation-preventing atmosphere. The precomposited powder has a plurality of powder particles, and each powder particle is formed of a matrix and reinforcing particles distributed within and encapsulated by the matrix. The matrix has a composition of a matrix metal such as molybdenum, hafnium, zirconium titanium, vanadium, niobium, tantalum, or tungsten, and a matrix non-metal of silicon, boron, or carbon. The reinforcement particle is silicon carbide, boron carbide, silicon nitride, or boron nitride.Type: GrantFiled: June 29, 2000Date of Patent: August 20, 2002Assignee: Plasma Technology, Inc.Inventor: Kamleshwar Upadhya