Superposed Diverse Or Multilayer Similar Coatings Applied Patents (Class 427/454)
  • Patent number: 10533433
    Abstract: A turbine blade of a gas turbine engine is described which includes an airfoil extending away from the hub platform to a blade tip. The airfoil defines a leading edge, a trailing edge, and a span-wise length extending between the platform and the blade tip. A hot-corrosion-resistant coating is located on the leading edge of the airfoil within a radially inner portion thereof, the radially inner portion extending away from the hub platform a desired distance along the span-wise length.
    Type: Grant
    Filed: July 27, 2016
    Date of Patent: January 14, 2020
    Assignee: PRATT & WHITNEY CANADA CORP.
    Inventors: Remy Synnott, Yulia Panchenko, Andrzej Paczoski
  • Patent number: 10371004
    Abstract: A layer system is provided having at least two layers, an inner layer on a boundary surface of a substrate, wherein the inner layer has a certain roughness in a region of the surface to an outer layer due to a coating processes, wherein a roughness of the boundary surface of the substrate is set in a targeted manner, or the boundary surface is machined, after it has been produced, such that the roughness of the boundary surface of the substrate has peaks and troughs that are at least 20% greater than the roughness of the interface if peaks and troughs were not to be present. As a result of the structured surface of the substrate, this roughness becomes positioned on an interface of the layers located above, and the adhesion of the layers to one another is thereby improved.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: August 6, 2019
    Assignee: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Alessandro Casu, Oliver Lusebrink
  • Patent number: 9343289
    Abstract: To manufacture a coating for an article for a semiconductor processing chamber, the article including a body of at least one of Al, Al2O3, or SiC, and a ceramic coating on the body. The ceramic coating includes a compound comprising Y2O3 in a range from about 50 mol % to about 75 mol %, ZrO2 in a range from about 10 mol % to about 30 mol %, and Al2O3 in a range from about 10 mol % to about 30 mol %, wherein the number of nodules per inch is in a range from about 30 nodules to about 45 nodules and the porosity is in a range from about 2.5% to about 3.2%.
    Type: Grant
    Filed: March 14, 2013
    Date of Patent: May 17, 2016
    Assignee: Applied Materials, Inc.
    Inventors: Jennifer Y. Sun, Biraja Prasad Kanungo, Dmitry Lubomirsky
  • Publication number: 20150118485
    Abstract: A gas turbine engine component includes a substrate formed of a high temperature resistant material and a corrosion resistant layer. The corrosion resistant layer is inert to the molten salt impurities and includes a refractory metal vanadate of formula MxVyOz, wherein M is selected from the group consisting of alkaline earth metals, group IV and V transition metals, rare-earth metals and their combinations, and wherein z=x+2.5y, or z=1.5x+2.5y, or z=2x+2.5y.
    Type: Application
    Filed: October 22, 2014
    Publication date: April 30, 2015
    Inventors: Limin WANG, Lawrence Bernard KOOL, Christopher Edward THOMPSON, Dalong ZHONG, Dalong ZHOU, Liming ZHANG
  • 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: 20150056535
    Abstract: A multi-layer coating for protection of metals and alloys against oxidation at high temperatures is provided. The invention utilizes a multi-layer ceramic coating on metals or alloys for increased oxidation-resistance, comprising at least two layers, wherein the first layer (3) and the second layer (4) both comprise an oxide, and wherein the first layer (3) has a tracer diffusion coefficient for cations Mm+, where M is the scale forming element of the alloy, and the second layer (4) has a tracer diffusion coefficient for oxygen ions O2? satisfying the following formula: ? ln ? ? p ? ( O 2 ) in ln ? ? p ? ( O 2 ) ex ? ( D O + m 2 ? D M ) ? ? ? ln ? ? p ? ( O 2 ) < 5 · 10 - 13 ? cm 2 ? / ? s wherein p(O2)in, p(O2)ex, DM, and DO are as defined herein.
    Type: Application
    Filed: September 8, 2014
    Publication date: February 26, 2015
    Inventors: Peter Vang Hendriksen, Lars Mikkelsen, Peter Halvor Larsen, Soeren Linderoth, Mogens Mogensen
  • Publication number: 20150030877
    Abstract: The invention refers to a process for the formation of a thermal barrier coating on a substrate, comprising the steps of: a) applying a bond coat on the substrate; b) subjecting the bond coat to a low activity aluminizing process, thus obtaining, above the bond coat, a temporary intermediate diffusion layer; c) applying, on the temporary intermediate diffusion layer, aluminium powder in suspension with a solvent or aqueous base, said aluminium powder having size distribution from 15 to 150 ?m; d) performing a thermal treatment in a vacuum at a pressure from 10?3 to 10?5 bars, at a temperature from 800° C. to 1050° C. and with an active phase having duration in the range of 60 minutes to 4 hours, thus obtaining above the bond coat an enriched intermediate diffusion layer; and e) applying a definitive barrier layer on said enriched intermediate diffusion layer.
    Type: Application
    Filed: August 3, 2012
    Publication date: January 29, 2015
    Applicant: GE AVIO S.r.I.
    Inventors: Maurizio Della Femina, Marco Rossi, Raffaele Casillo, Carlo Silvestro
  • Publication number: 20140377473
    Abstract: Coating systems and processes by which the coating systems can be deposited to be resistant to contaminants, and particularly resistant to infiltration and damage caused by CMAS. The coating systems include inner and outer ceramic layers, each having a microstructure characterized by splats and horizontal porosity. The inner ceramic layer consists essentially of zirconia stabilized by about 6 to about 9 weight percent yttria. The outer ceramic layer overlies and contacts the inner ceramic layer to define the outermost surface of the coating system. The outer ceramic layer consists essentially of zirconia stabilized by about 25 to about 75 weight percent yttria, has a thickness that is less than the thickness of the inner ceramic layer, and has a porosity level that is lower than that of the inner ceramic layer.
    Type: Application
    Filed: September 10, 2014
    Publication date: December 25, 2014
    Inventors: BANGALORE ASWATHA NAGARAJ, THOMAS JOHN TOMLINSON
  • Patent number: 8859116
    Abstract: A multi-layer coating for protection of metals and alloys against oxidation at high temperatures is provided. The invention utilizes a multi-layer ceramic coating on metals or alloys for increased oxidation-resistance, comprising at least two layers, wherein the first layer (3) and the second layer (4) both comprise an oxide, and wherein the first layer (3) has a tracer diffusion coefficient for cations Mm+, where M is the scale forming element of the alloy, and the second layer (4) has a tracer diffusion coefficient for oxygen ions O2? satisfying the following formula: ? ln ? ? p ? ( O 2 ) in ln ? ? p ? ( O 2 ) ex ? ( D O + m 2 ? D M ) ? ? ? ln ? ? p ? ( O 2 ) < 5 · 10 - 13 ? ? cm 2 / s wherein p(O2)in, p(O2)ex, DM and DO are as defined herein.
    Type: Grant
    Filed: April 24, 2007
    Date of Patent: October 14, 2014
    Assignee: Technical University of Denmark
    Inventors: Peter Vang Hendriksen, Lars Mikkelsen, Peter Halvor Larsen, Soeren Linderoth, Mogens Mogensen
  • Patent number: 8859052
    Abstract: Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability include providing a component, applying an environmental barrier coating to the component, where the environmental barrier coating includes a CMAS mitigation composition selected from the group consisting of zinc aluminate spinel, alkaline earth zirconates, alkaline earth hafnates, rare earth gallates, beryl, and combinations thereof.
    Type: Grant
    Filed: November 30, 2012
    Date of Patent: October 14, 2014
    Assignee: General Electric Company
    Inventors: Glen Harold Kirby, Brett Allen Boutwell, John Frederick Ackerman
  • Patent number: 8852682
    Abstract: A high strength composite particle comprised of a series of incrementally applied resin microlayer coatings such that each of the microlayer partial coatings are interleaved with each other is described. Methods of making the composite particles, as well as methods of using such particles as a proppant in oil and gas well hydraulic fracturing are also described.
    Type: Grant
    Filed: October 18, 2006
    Date of Patent: October 7, 2014
    Assignee: Fairmount Minerals, Ltd.
    Inventors: A. Richard Sinclair, Syed Akbar, Patrick R. Okell
  • Publication number: 20140272169
    Abstract: A method of making a multilayer environmental barrier coating for a ceramic matrix composite is provided, comprising the steps of: plasma spray coating an oxide-based bond coat over top of the ceramic matrix composite and depositing a columnar top coat over the oxide-based bond coat.
    Type: Application
    Filed: February 12, 2014
    Publication date: September 18, 2014
    Inventor: Kang N. Lee
  • Publication number: 20140272168
    Abstract: A method of making a multilayer environmental barrier coating for a ceramic matrix composite is provided, comprising the steps of: plasma spray coating an oxide-based bond coat over top of the ceramic matrix composite and depositing a columnar top coat over the oxide-based bond coat.
    Type: Application
    Filed: February 12, 2014
    Publication date: September 18, 2014
    Inventor: Kang N. Lee
  • Publication number: 20140260434
    Abstract: The invention relates to a device delivering filaments of molten material, especially glass, by Joule heating using a power supply, comprising side plates, a bottom plate provided with nozzles for the flow of the molten material and optionally an upper screen, is characterized in that at least one of these parts capable of being in contact with the molten material is formed by: a solid part made of iron-based alloy having a melting point above 1450° C. that forms a substrate, a metal tie layer formed on at least one portion of the surface of the substrate, a ceramic layer covering the metal tie layer, the metal layer and the ceramic layer forming a diffusion barrier to the components of the alloy that forms the substrate, and a protective coating layer made of platinum or platinum alloy, deposited directly on the ceramic layer.
    Type: Application
    Filed: October 2, 2012
    Publication date: September 18, 2014
    Applicant: SAINT-GOBAIN ADFORS
    Inventors: Cyril Condolf, Achim Breuer
  • Publication number: 20140242417
    Abstract: A method for the photocatalytically active coating of surfaces is presented and described, as well as an article (1) photocatalytically actively coated according to this method. The object of providing a method for the photocatalytically active coating of, in particular, metallic surfaces, whereby a permanently stable coating is produced without negatively affecting the photocatalytic activity of the layer, is achieved by a method, in which a substrate article is prepared which has a surface, a metallic adhesion-promoting layer is applied to the surface of the substrate article, a photocatalytically active layer consisting of one or more metal oxides is applied to the adhesion-promoting layer, wherein the metallic adhesion-promoting layer and the surface of the substrate article consist of a different material and the adhesion-promoting layer is selected such that it is not oxidized or reduced by the photocatalytically active layer.
    Type: Application
    Filed: September 18, 2012
    Publication date: August 28, 2014
    Applicant: LINDE AKTIENGESELLSCHAFT
    Inventors: Jan-Oliver Kliemann, Henning Gutzmann, Thomas Klassen, Frank Gaertner
  • Publication number: 20140227452
    Abstract: A composition based on a novel MCrAlY formulation is provided for the production of protective coatings. The specific combination of the constituents of the MCrAlY formulation advantageously allows significantly high loadings of ceramic (metal oxide) while still retaining the ability to selectively oxidize aluminum to form alumina scale, a property previously not attainable with conventional MCrAlY materials when loaded with ceramics at levels of 15-45 weight percent. The alumina scale in combination with the modified MCrAlY formulation act as a barrier to specific detrimental oxide formations. The compositions of the present invention can act as protective coatings for a wide array of applications.
    Type: Application
    Filed: February 6, 2014
    Publication date: August 14, 2014
    Inventor: William JAROSINSKI
  • Patent number: 8802199
    Abstract: An apparatus for applying segmented ceramic coatings includes means for supporting and moving one or more substrates; one or more heat sources disposed proximate to one or more substrates, wherein at least one of the heat sources is positioned to apply a heat stream to pre-heat a thermal gradient zone on a surface of a substrate; a material deposition device disposed proximate to one or more heat sources, wherein the material deposition device is positioned to deposit a material on a deposition area located behind the thermal gradient zone on the surface; and means for monitoring a surface temperature of one or more substrates.
    Type: Grant
    Filed: December 31, 2009
    Date of Patent: August 12, 2014
    Assignee: United Technologies Corporation
    Inventors: Christopher W. Strock, Charles G. Davis
  • Patent number: 8784944
    Abstract: A ceramic thermal barrier coating having improved erosion resistance includes a metallic layer and a ceramic layer positioned on the metallic layer. The ceramic layer includes a first powder, a second powder, and a third powder. The first powder and the second powder are alloyed together prior to being mixed with the third powder.
    Type: Grant
    Filed: November 29, 2006
    Date of Patent: July 22, 2014
    Assignee: United Technologies Corporation
    Inventors: Kevin W. Schlichting, Paul H. Zajchowski
  • Patent number: 8740007
    Abstract: A cooking utensil and a manufacturing method thereof are provided. The cooking utensil includes a cooking body, a first metal-ceramic composite layer having an electromagnetic property and a second metal-ceramic composite layer having a heat conductive property. The cooking body has an external bottom surface. The first metal-ceramic composite layer is disposed on the external bottom surface of the cooking body. The second metal-ceramic composite layer is disposed on the first metal-ceramic composite layer. The cooking utensil is suitable for both an induction cooker and a gas burner.
    Type: Grant
    Filed: December 21, 2010
    Date of Patent: June 3, 2014
    Assignee: Industrial Technology Research Institute
    Inventors: Ming-Sheng Leu, Wu-Han Liu, Wei-Tien Hsiao, Chang-Chih Hsu, Mao-Shin Liu, Zhong-Ren Wu
  • Publication number: 20140141276
    Abstract: A method for applying a protective layer resistant to high-temperature degradation by corrosion and erosion to a base metal, comprises: applying a MCrAlY-based bond layer to the base metal; coating, by overaluminizing with an Al diffusion layer, the bond layer; subjecting the Al diffusion layer (14) to abrasion treatment so that an outer build-up layer is removed from the Al diffusion layer; and applying a ceramic thermal barrier coating of yttria partially stabilized zirconia to the remaining Al diffusion layer. The ceramic thermal barrier coating is applied to the remaining Al diffusion layer by air plasma spraying. The applied bond layer is subjected to a polishing treatment before being overaluminized such that a surface roughness of Ra?2 ?m is produced at the bond layer.
    Type: Application
    Filed: May 31, 2012
    Publication date: May 22, 2014
    Inventors: Norbert Czech, Sharad Chandra, Roland Herzog
  • Publication number: 20140134456
    Abstract: A coating for a metal surface that provides excellent resistance to both electrochemical corrosion and mechanical insult is provided. The coating involves at least an inner coating that is a sacrificial anodic layer and an outer coating that is a protective dielectric material made of inorganic metal oxide. Some versions of the coating include an intermediate layer as well that serves to improve adhesion between the coatings and may provide additional galvanic protection. Although the coating can be made by a variety of methods, advanced methods of spray application are provided for making high-quality lightweight versions the coating.
    Type: Application
    Filed: January 23, 2014
    Publication date: May 15, 2014
    Applicant: United States Pipe and Foundry Company, LLC
    Inventors: A. Michael HORTON, William H. Owen
  • Patent number: 8658255
    Abstract: Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability involving providing a component; applying an environmental barrier coating to the component, the environmental barrier coating having a separate CMAS mitigation layer including a CMAS mitigation composition selected from rare earth elements, rare earth oxides, zirconia, hafnia partially or fully stabilized with alkaline earth or rare earth elements, zirconia partially or fully stabilized with alkaline earth or rare earth elements, magnesium oxide, cordierite, aluminum phosphate, magnesium silicate, and combinations thereof.
    Type: Grant
    Filed: December 19, 2008
    Date of Patent: February 25, 2014
    Assignee: General Electric Company
    Inventors: Glen Harold Kirby, Brett Allen Boutwell, Ming Fu, Bangalore Aswatha Nagaraj, Brian Thomas Hazel
  • Patent number: 8650753
    Abstract: A seal (48) between a compressor rotor blade (26) and compressor casing (28) comprises an abradable structure (59) on the compressor casing (28). The abradable structure (59) comprises a metallic foam (60) having pores (66, 68). The metallic foam (60) has a first a region (62) and a second region (64). The first region (62) of the metallic foam (60) is arranged adjacent to the compressor casing (28) and the second region (64) of the metallic foam (60) is spaced from the compressor casing (28) by the first region (62) of the metallic foam (60). The pores (68) of the second region (64) of the metallic foam (60) contain an abradable material (70) and the pores (66) of the first region (62) of the metallic foam (60) do not contain an abradable material.
    Type: Grant
    Filed: October 8, 2009
    Date of Patent: February 18, 2014
    Assignee: Rolls-Royce, PLC
    Inventors: Christopher Sellars, Glen Pattinson, John T Gent
  • Patent number: 8623446
    Abstract: The invention is directed to an ion plasma deposition (IPD) method adapted to coat polymer surfaces with highly adherent antimicrobial films. A controlled ion plasma deposition (IPD) process is used to coat a metal or polymer with a selected metal/metal oxide. Exposing the coated surface to ultraviolet light significantly improves the antimicrobial properties of the deposited coatings.
    Type: Grant
    Filed: October 3, 2006
    Date of Patent: January 7, 2014
    Assignee: Metascape LLC
    Inventors: Terrence S. McGrath, Deidre Sewell, Daniel M. Storey
  • Patent number: 8617637
    Abstract: A thermal spraying method includes forming a coating layer of heat resistant resin on the whole spray area of the metal surface, securely fixing a test piece of the same material as that of the metal as a constituent of heat resistant equipment on the surface of the coating layer, spraying a heat shield coating material onto the test piece, detaching the test piece from the surface of the coating layer, inspecting the condition of spray and setting spray conditions, removing the coating layer and, under the above set spray conditions, spraying the heat shield coating material onto the metal surface to thereby form a heat shield coating layer.
    Type: Grant
    Filed: June 25, 2008
    Date of Patent: December 31, 2013
    Assignee: Mitsubishi Heavy Industries, Ltd.
    Inventors: Hitoshi Morimoto, Yoriaki Inoue
  • Publication number: 20130344255
    Abstract: Disclosed are a thermal spray coating material which greatly improves corrosion resistance, as compared to conventional Al2O3 and Y2O3 crystalline coatings and Al—Y—O and Al—Zr—O amorphous thermal spray coatings, a production method of the coating material, and a coating method using the same. The thermal spray coating material has a chemical formula of Y2xZr1-xOx+2, where x ranges from 0.19 to 0.83, preferably from 0.35 to 0.69. Accordingly, it is possible to produce a coating material for use in a chamber of vacuum plasmas equipment or internal parts of the chamber can be produced, which improves the corrosion resistance of a protective coating film upon ceramic thermal spray coating and lengthens the lifespan of parts.
    Type: Application
    Filed: June 12, 2013
    Publication date: December 26, 2013
    Inventors: Hyun-Kwang SEOK, Yu-Chan KIM, Eun-Young CHOI, Kyeong-Ho BAIK, Kyung-Hun BYUN, Hoon JEONG
  • Publication number: 20130260132
    Abstract: A tubine engine component has a substrate, a thermal barrier layer deposited onto the substrate, and a sealing layer of ceramic material deposited on an outer surface of the thermal barrier layer for limiting molten sand penetration. The thermal barrier layer and sealing layer are formed by suspension plasma spraying. A preferred sealing layer is gadolinium zirconate.
    Type: Application
    Filed: April 2, 2012
    Publication date: October 3, 2013
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Brian T. Hazel, David A. Litton, Michael J. Maloney
  • Patent number: 8529999
    Abstract: A process of coating an article includes the steps of (1) forming a layer of a ceramic based compound on an article; (2) providing a solution containing a metal as a particulate having a diameter of about 10 nanometers to about 1000 nanometers and present in an amount of about 25 percent to about 50 percent by volume of the solution; (3) contacting the ceramic based compound layer with the solution; (4) drying the article; and (5) optionally repeating steps (3) and (4).
    Type: Grant
    Filed: August 24, 2009
    Date of Patent: September 10, 2013
    Assignee: United Technologies Corporation
    Inventors: Michael J. Maloney, David A. Litton, Kevin W. Schlichting, Melvin Freling, John G. Smeggil, David B. Snow
  • Publication number: 20130224453
    Abstract: In a method for coating a substrate, a ceramic first layer is suspension plasma sprayed and is at least about as tough as 7YSZ. A ceramic second layer is applied over the first layer and is less tough than the first layer.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Brian T. Hazel, Benjamin J. Zimmerman, David A. Litton
  • Publication number: 20130192302
    Abstract: Coated crucibles for holding molten material are disclosed. In some embodiments, the crucibles are used to prepare multicrystalline silicon ingots by a directional solidification process. Methods for preparing such crucibles and methods for preparing silicon ingots by use of such crucibles are also disclosed.
    Type: Application
    Filed: January 11, 2013
    Publication date: August 1, 2013
    Inventor: MEMC Singapore Pte. Ltd. (UEN200614794D)
  • Patent number: 8460796
    Abstract: A composite body that is spall resistant and comprises a substantially discontinuous cermet phase in a substantially continuous metal rich matrix phase. The composite body is typically bonded to a substrate to form a hardfacing on the substrate. The composite body exhibits ductile phase toughening with a strain to failure of at least about 2 percent, a modulus of elasticity of less than about 46 million pounds per square inch, and a density of less than about 7 grams per cubic centimeter. The metal rich matrix phase between the ceramic rich regions in the composite body has an average minimum span of about 0.5 to 8 microns to allow ductility in the composite body. The composite body has a Vicker's hardness number of greater than approximately 650. The discontinuous cermet phase is in the form of ceramic rich regions embedded within the composite body, and it includes ceramic particles and a cermet binder. The ceramic particles having a Moh's hardness of at least approximately 7.
    Type: Grant
    Filed: February 3, 2010
    Date of Patent: June 11, 2013
    Assignee: Mesocoat, Inc.
    Inventor: Andrew J. Sherman
  • Publication number: 20130115418
    Abstract: Embodiments relate to a coated substrate and a method of making and using the same. A plasma-spray coated layer may be formed on a substrate, wherein the plasma-sprayed coated layer comprises a rare-earth oxide (e.g., yttrium oxide), a rare-earth fluoride (e.g. yttrium fluoride), or a rare-earth silicate (e.g. yttrium silicate). An exposed surface of the plasma-spray coated layer may be irradiated to form a treated portion of the layer, wherein the treated portion of the layer has a mean spacing of local peaks (S value) between about 100 and 200 microns. A second layer may be formed on the treated portion of the plasma-spray coated layer, wherein the second layer comprises a dielectric material.
    Type: Application
    Filed: October 19, 2012
    Publication date: May 9, 2013
    Applicant: CoorsTek, Inc.
    Inventor: CoorsTek, Inc.
  • Publication number: 20130052451
    Abstract: An insulation coating method for a metal base comprises a thermal spraying step, an impregnation step, and a beam irradiation step. In the thermal spraying step, a first insulation coating is formed by thermally spraying a first metal oxide to the surface of the metal base. In the impregnation step, pores formed in the surface of the first insulation coating are impregnated with a sol that contains, as a dispersoid, a metal oxide, a hydrate of a metal oxide, or a metal hydroxide. In the beam irradiation step, a second insulation coating that is composed of a second metal oxide is formed by irradiating the first insulation coating and the sol with a high energy beam after the impregnation step.
    Type: Application
    Filed: October 26, 2012
    Publication date: February 28, 2013
    Inventors: Takamichi Sano, Shinya Miyaji, Shinji Saito
  • Patent number: 8372488
    Abstract: Methods and apparatus for thermal barrier coatings are provided. The thermal barrier coating system includes a bond coat, a first thermal barrier coating comprising a thermal conductivity, kA having a first value, and a second thermal barrier coating including a thermal conductivity, kB having a second value wherein the second value is different than the first value.
    Type: Grant
    Filed: May 1, 2006
    Date of Patent: February 12, 2013
    Assignee: General Electric Company
    Inventors: Ravindra Annigeri, David Vincent Bucci
  • Publication number: 20130017338
    Abstract: A plasma spray gun comprises a nozzle, an upstream powder injector, and a downstream powder injector. The upstream powder injector is disposed outside the nozzle and axially adjacent a nozzle outlet. The downstream powder injector is disposed axially downstream of the first upstream powder injector. The downstream powder injector is operative in a first coating mode, and the upstream powder injector is operative in a second coating mode.
    Type: Application
    Filed: July 13, 2011
    Publication date: January 17, 2013
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Christopher W. Strock, Robert D. Richard, Steven Lemay
  • Patent number: 8343589
    Abstract: Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability including providing a component; applying an environmental barrier coating to the component, the environmental barrier coating having a separate CMAS mitigation layer including a CMAS mitigation composition selected from the group consisting of zinc aluminate spinel, alkaline earth zirconates, alkaline earth hafnates, rare earth gallates, beryl, and combinations thereof.
    Type: Grant
    Filed: December 19, 2008
    Date of Patent: January 1, 2013
    Assignee: General Electric Company
    Inventors: Glen Harold Kirby, Brett Allen Boutwell, John Frederick Ackerman
  • Patent number: 8337956
    Abstract: A wafer has a rare earth oxide layer disposed, typically sprayed, on a substrate. It is useful as a dummy wafer in a plasma etching or deposition system.
    Type: Grant
    Filed: December 20, 2011
    Date of Patent: December 25, 2012
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Toshihiko Tsukatani, Takao Maeda, Junichi Nakayama, Hirofumi Kawazoe, Masaru Konya, Noriaki Hamaya, Hajime Nakano
  • Publication number: 20120308733
    Abstract: To manufacture a thermal barrier coating structure on a substrate surface, a working chamber having a plasma torch is provided, a plasma jet is generated in that a plasma gas is conducted through the plasma torch and is heated therein by means of electric gas discharge, electromagnetic induction or microwaves, and the plasma jet is directed to the surface of a substrate introduced into the working chamber. To manufacture the thermal barrier coating, a voltage is additionally applied between the plasma torch and the substrate to generate an arc between the plasma torch and the substrate and the substrate surface is cleaned by means of the light arc, wherein the substrate remains in the working chamber after the arc cleaning and an oxide layer is generated on the cleaned substrate surface and a thermal barrier coating is applied by means of a plasma spray process.
    Type: Application
    Filed: October 7, 2011
    Publication date: December 6, 2012
    Inventors: Konstantin von Niessen, Malko Gindrat, Richard K. Schmid
  • Publication number: 20120298503
    Abstract: This invention relates to a method for preparing a bimetallic titania-based catalyst for use in hydrodesulfurization reactions.
    Type: Application
    Filed: May 24, 2011
    Publication date: November 29, 2012
    Inventors: Ahmad D. HAMMAD, Esam Zaki Hamad, George Panagiotou, Christos Kordulis, Demetrios Theleritis
  • Patent number: 8316647
    Abstract: Methods and apparatuses are provided for protecting a catalyst within a combustor. In one embodiment, a catalytic reactor includes a protective coating that may be chemically removed or mechanically removed while the catalytic reactor is disposed in a combustor.
    Type: Grant
    Filed: January 19, 2009
    Date of Patent: November 27, 2012
    Assignee: General Electric Company
    Inventors: Gilbert Otto Kraemer, Cristina Colindres Kraemer
  • Patent number: 8318261
    Abstract: The disclosure provides a method of producing thermally sprayed Al2O3 coatings having a high content of corundum without any property-reducing additives. The coatings may be utilized particularly in the field of electrical insulation, as a dielectric, and as protection from wear. The thermally sprayed Al2O3 coatings have a porosity of no more than 19%, and a high content of ?-Al2O3 (content of corundum) of at least 72% by volume. The coatings have a specific electrical resistance of >1·1012 Ohms·cm, and a purity of >97%. The production of said coatings is carried out utilizing aqueous or alcoholic suspensions made from substantially pure ?-Al2O3, having a grain size of >100 nm by thermal spraying.
    Type: Grant
    Filed: May 28, 2009
    Date of Patent: November 27, 2012
    Assignee: Fraunhofer-Gesellschaft zur Foerderung der Angewandten Forschung E.V.
    Inventors: Filofteia-Laura Toma, Lutz-Michael Berger, Carl Christoph Stahr, Tobias Naumann, Stefan Langner
  • Patent number: 8293335
    Abstract: Yttria-coated ceramic components of semiconductor material processing apparatuses include a substrate and at least one yttria-containing coating on the substrate. The components are made by applying a first yttria-containing coating on a ceramic substrate, which can be a green body of the ceramic material. The coated green body is sintered. The first yttria-containing coating can be treated to remove attached yttria particles resulting from the sintering. In another embodiment, a second yttria-containing coating can be thermally sprayed on the first yttria-containing coating to cover the particles.
    Type: Grant
    Filed: March 8, 2007
    Date of Patent: October 23, 2012
    Assignee: Lam Research Corporation
    Inventor: Chris Chang
  • Patent number: 8197950
    Abstract: This invention relates to dense, vertically cracked thermal barrier coatings made from high purity yttria or ytterbia stabilized zirconia powders. The high purity yttria or ytterbia stabilized zirconia powder consisting essentially of less than about 0.01 weight percent silicon dioxide (silica), less than about 0.002 weight percent aluminum oxide (alumina), less than about 0.005 weight percent calcium oxide, less than about 0.005 weight percent ferric oxide, less than about 0 to about 0.002 weight percent magnesium oxide, less than about 0 to about 0.005 weight percent titanium dioxide, from about 1.5 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria), less than 0.1 weight percent other impurity oxides, and the balance zirconium oxide (zirconia) and the balance zirconium oxide (zirconia).
    Type: Grant
    Filed: September 12, 2011
    Date of Patent: June 12, 2012
    Assignee: Praxair S.T. Technology, Inc.
    Inventors: Thomas Alan Taylor, Danny Lee Appleby, Ann Bolcavage, Albert Feuerstein, Neil Hitchman
  • Patent number: 8192807
    Abstract: A method and apparatus for making an optical fiber preform, including injecting a plasma gas source into the first end of a tubular member; generating a ring plasma flame with the plasma gas source flowing through a plasma gas feeder nozzle, the plasma gas feeder nozzle including: an inner tube, an outer tube, wherein the plasma gas source is injected between the inner tube and the outer tube to produce the ring plasma flame, such that at least a portion of the ring plasma flame is directed radially toward the inner surface of the tubular member; traversing the tubular member along the longitudinal axis relative to the plasma flame; depositing at least one soot layer on the interior surface of the tubular member by introducing reagent chemicals into the plasma flame; and fusing all of the soot layers into a glass material on the interior surface of the tubular member.
    Type: Grant
    Filed: August 6, 2010
    Date of Patent: June 5, 2012
    Assignee: Silica Tech, LLC
    Inventors: Mikhail I. Guskov, Mohd A. Aslami, Evgueni B. Danilov, Dau Wu
  • Publication number: 20120111872
    Abstract: A cooking utensil and a manufacturing method thereof are provided. The cooking utensil includes a cooking body, a first metal-ceramic composite layer having an electromagnetic property and a second metal-ceramic composite layer having a heat conductive property. The cooking body has an external bottom surface. The first metal-ceramic composite layer is disposed on the external bottom surface of the cooking body. The second metal-ceramic composite layer is disposed on the first metal-ceramic composite layer. The cooking utensil is suitable for both an induction cooker and a gas burner.
    Type: Application
    Filed: December 21, 2010
    Publication date: May 10, 2012
    Applicant: INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE
    Inventors: Ming-Sheng Leu, Wu-Han Liu, Wei-Tien Hsiao, Chang-Chih Hsu, Mao-Shin Liu, Zhong-Ren Wu
  • Patent number: 8168261
    Abstract: The invention provides a process for applying a heat shielding coating system on a metallic substrate. The coating system comprises at least three individual layers selected from the group of barrier layer, hot gas corrosion protection layer, protection layer, heat barrier layer, and smoothing layer. The coating system is applied to the metallic substrate by low pressure plasma spraying in a single operation cycle. This process enables the layers to be applied in an arbitrary sequence. The process is preferably used in applying a coating system to a turbine blade, particularly a stator or a rotor blade of a stationary gas turbine or of an aircraft engine, or to another component in a stationary or aircraft turbine that is subjected to hot gas.
    Type: Grant
    Filed: March 21, 2002
    Date of Patent: May 1, 2012
    Assignee: Sulzer Metco A.G.
    Inventors: Ing Michael Loch, Gérard Barbezat
  • Publication number: 20120099972
    Abstract: An abrasive coating is formed on a rotor shaft that rotates with respect to cantilevered vanes. The coating is formed by thermal spray techniques and comprises a ceramic layer on a metal bond coat. The coating surface is roughened by crush grinding or by grit blasting to increase the abradability of the surface.
    Type: Application
    Filed: October 25, 2010
    Publication date: April 26, 2012
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Changsheng Guo, Christopher W. Strock, Thomas W. Stowe, Paul W. Baumann
  • Patent number: 8163353
    Abstract: A fuel electrode anode (18) for a solid oxide fuel cell is made by presenting a solid oxide fuel cell having an electrolyte surface (15), mixing copper powder with solid oxide electrolyte in a mixing step (24, 44) to provide a spray feedstock (30,50) which is fed into a plasma jet (32, 52) of a plasma torch to melt the spray feed stock and propel it onto an electrolyte surface (34, 54) where the spray feed stock flattens into lamellae layer upon solidification, where the layer (38, 59) is an anode coating with greater than 35 vol. % based on solids volume.
    Type: Grant
    Filed: July 8, 2008
    Date of Patent: April 24, 2012
    Assignee: Siemens Energy, Inc.
    Inventor: Chun Lu
  • Publication number: 20120088034
    Abstract: A wafer has a rare earth oxide layer disposed, typically sprayed, on a substrate. It is useful as a dummy wafer in a plasma etching or deposition system.
    Type: Application
    Filed: December 20, 2011
    Publication date: April 12, 2012
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Toshihiko Tsukatani, Takao Maeda, Junichi Nakayama, Hirofumi Kawazoe, Masaru Konya, Noriaki Hamaya, Hajime Nakano