Metal Or Metal Alloy Coating Patents (Class 427/455)
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Publication number: 20080090071Abstract: The present invention relates to a method of coating a surface with nanoparticles, to a nanostructured coating that can be obtained by this method, and also to a device for implementing the method of the invention. The method is characterized in that it comprises an injection of a colloidal sol of said nanoparticles into a plasma jet that sprays them onto said surface. The device (1) comprises: a plasma torch (3); at least one container (5) containing the colloidal sol (7) of nanoparticles; a device (9) for fixing and for moving the substrate(S); and a device (11) for injecting the colloidal sol into the plasma jet (13) of the plasma torch. The present invention has applications in optical, electronic and energy devices (cells, thermal barriers) comprising a nanostructured coating that can be obtained by the method of the invention.Type: ApplicationFiled: October 20, 2005Publication date: April 17, 2008Applicant: COMMISSARIAT A L'ENERGIE ATOMIQUEInventors: Karine Valle, Philippe Belleville, Karine Wittmann-Teneze, Luc Bianchi, Franck Blein
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Publication number: 20080081122Abstract: The present invention is directed to an improved process for manufacturing a rotary anode for an x-ray tube, said rotary anode comprising a molybdenum support member on which a target layer consisting essentially of tungsten or a tungsten-rhenium alloy is provided by plasma spraying, the improvement comprising: a) preheating the support member to a temperature of from 1150° C. to 1600° C., b) placing the support member in a gaseous atmosphere containing hydrogen and having a pressure of from 0.5 to 0.9 bars and wherein hydrogen is present in a molar ratio of hydrogen to tungsten dioxide of from 5:1 to 50:1, and c) plasma spraying the target layer onto the support layer in said gaseous atmosphere. The invention is also directed to the anode produced by the process.Type: ApplicationFiled: October 3, 2006Publication date: April 3, 2008Inventors: Leah F. Haywiser, Leonid N. Shekhter
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Patent number: 7351450Abstract: Disclosed is a method for repairing defects in kinetically sprayed surfaces. The typical defects comprise isolated or connected conical shaped holes in the kinetic spray coating. The repair involves thermally spraying a molten material into the defective area to fill in the cone followed by continued kinetic spraying to complete the coating.Type: GrantFiled: October 2, 2003Date of Patent: April 1, 2008Assignee: Delphi Technologies, Inc.Inventors: Brian K Fuller, Alaa A. Elmoursi, Kenneth M Rahmoeller
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Publication number: 20080072790Abstract: Methods of making a metallic or cerment coating include suspending solid fine metal or cerment particles in a liquid to form a liquid feedstock and injecting the liquid feedstock into an high-velocity oxygen fuel flame gun to thermally spray the liquid feedstock on a substrate to form a coating thereon.Type: ApplicationFiled: September 20, 2007Publication date: March 27, 2008Applicant: Inframat CorporationInventors: Xinqing Ma, Jeffrey Roth, T. Danny Xiao
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Publication number: 20080076328Abstract: A method for producing surface coatings on gas turbine components and/or for measuring abrasive material residues on gas turbine components, including: -abrasively blasting a surface of the component using an abrasive material, a portion of this abrasive material remaining on or in this surface of the component; -detecting abrasive material which has remained on or in the surface of the component; and -applying a coating to the surface of the component is disclosed.Type: ApplicationFiled: June 25, 2007Publication date: March 27, 2008Applicant: MTU Aero Engines GmbHInventors: Guenter Zenzinger, Herbert Zisik
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Patent number: 7341758Abstract: An article having a thermal-spray coating thereon is prepared by thermally spraying a coating material onto a surface of a substrate article. The coated article is nondestructively tested by directing a transmitted ultrasonic signal into the coated article, receiving a received ultrasonic signal from the coated article, and evaluating a near-bondline region of the coated article located adjacent to the surface of the article using the received ultrasonic signal.Type: GrantFiled: April 24, 2003Date of Patent: March 11, 2008Assignee: General Electric CompanyInventors: Matthew Stewart, Thomas J. Tomlinson, David J. Dietz, Patsy Augustine Ruzzo
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Patent number: 7341533Abstract: A continuously variable transmission (CVT) includes an aluminum housing member having a bore formed therein. A rotatable pulley member is supported on a bearing within the bore. The bore includes a layer of thermal spray coating for improved wear resistance so that the bore supports the bearing without a steel sleeve therebetween.Type: GrantFiled: October 24, 2003Date of Patent: March 11, 2008Assignee: General Motors CorporationInventors: Yucong Wang, Sime Stavreski, Jasbir Singh
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Patent number: 7339142Abstract: The invention relates to a heating device (1) comprising a metallic substrate (2) whose at least one part is coated with a self-cleaning coating. The inventive coating consists of an external layer (4) contacting ambient air and comprising at least one type of oxidation catalyst selected from platinoid oxides, at least one internal layer (3) which is arranged between the metallic substrate and the external layer and comprises at least one type of oxidation catalyst selected from transition elements oxides of 1b group. The inventive heating device can be embodied, for instance in the form of an iron soleplate consisting of a heating base (6) provided with heating elements (7) or a cooking appliance. Said metallic substrate can be covered with an intermediary enamel layer (5). A method for coating the metallic substrate of a heating device with said coating is also disclosed.Type: GrantFiled: November 20, 2003Date of Patent: March 4, 2008Assignee: SEB S.A.Inventors: Stéphanie Pessayre, Henry Boulud
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Publication number: 20070275174Abstract: A method of coating a fishing lure such as a fly and/or a fly fishing line with a fluorocarbon dissolved or dispersed in a liquid diluent is disclosed.Type: ApplicationFiled: May 23, 2007Publication date: November 29, 2007Inventors: Eric L. Hanson, Eric L. Bruner
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Patent number: 7294413Abstract: A protected article includes a substrate having a surface, and a protective system overlying and contacting a first portion of the surface of the substrate. The protective system has a nickel-base superalloy bond coat, an aluminide layer overlying and contacting the bond coat, and a dense vertically microcracked ceramic thermal barrier coating overlying and contacting the aluminide layer.Type: GrantFiled: March 7, 2005Date of Patent: November 13, 2007Assignee: General Electric CompanyInventors: Bangalore Aswatha Nagaraj, D. Keith Patrick, Thomas John Tomlinson, David Walter Parry
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Patent number: 7291384Abstract: The piston ring of the present invention comprises a thermal spray coating comprising chromium carbide particles having an average particle size of 5 ?m or less, and a matrix metal composed of a Ni—Cr alloy or a Ni—Cr alloy and Ni at least on an outer peripheral surface, said thermal spray coating having an average pore diameter of 10 ?m or less and a porosity of 8% or less by volume. A piston ring having excellent wear resistance, scuffing resistance and peeling resistance with little attackability on a mating member is obtained by forming a homogeneous thermal spray coating having a fine microstructure.Type: GrantFiled: October 15, 2003Date of Patent: November 6, 2007Assignee: Kabushiki Kaisha RikenInventors: Ryou Obara, Katsumi Takiguchi, Yukio Hosotsubo
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Publication number: 20070254181Abstract: 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: ApplicationFiled: May 1, 2006Publication date: November 1, 2007Inventors: Ravindra Annigeri, David Vincent Bucci
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Patent number: 7278353Abstract: Shaped charge liners are made of reactive materials formed by thermal spray techniques. The thermally sprayed reactive shaped charge materials have low porosity and high structural integrity. Upon detonation, the reactive materials of the shaped charge liner undergo an exothermic reaction that raises the temperature and the effectiveness of the liner.Type: GrantFiled: May 5, 2004Date of Patent: October 9, 2007Assignee: Surface Treatment Technologies, Inc.Inventors: Timothy Langan, Michael A. Riley, W. Mark Buchta
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Patent number: 7279078Abstract: A process for coating a non-uniform, thin-film, dichroic pattern to a wheel rim or motorcycle part. The thin-film coating adds a colored or iridescent pattern to the wheel rim or motorcycle part, while maintaining other characteristics, such as brilliance, shine, durability and general appearance. The coating is intentionally non-uniform. It may be varied, and may have different patterns and color among different articles, and even among different areas on the same article. The thin-film coating may be added by various techniques known in the art, but is preferably applied by sputtering a silicon or titanium target to obtain the thin-film on a chromed wheel rim.Type: GrantFiled: April 25, 2005Date of Patent: October 9, 2007Inventors: Micha Kapourchali, Nima Khalilian
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Patent number: 7265048Abstract: A method and apparatus for forming layers on a substrate comprising depositing a metal seed layer on a substrate surface having apertures, depositing a transition metal layer over the copper seed layer, and depositing a bulk metal layer over the transition metal layer. Also a method and apparatus for forming a via through a dielectric to reveal metal at the base of the via, depositing a transition metal layer, and depositing a first metal layer on the transition metal layer. Additionally, a method and apparatus for depositing a transition metal layer on an exposed metal surface, and depositing a layer thereover selected from the group consisting of a capping layer and a low dielectric constant layer.Type: GrantFiled: March 1, 2005Date of Patent: September 4, 2007Assignee: Applied Materials, Inc.Inventors: Hua Chung, Seshadri Ganguli, Christophe Marcadal, Jick M. Yu
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Patent number: 7254888Abstract: A method of fabricating a heat sink includes preparing a surface of a graphite-based substrate and removing particulate matter generated from the preparation of the surface of the substrate. A metal-based coating is applied at the surface of the prepared substrate. The prepared substrate having the metal-based coating is arranged to form a heat sink structure.Type: GrantFiled: April 7, 2005Date of Patent: August 14, 2007Assignee: International Business Machines CorporationInventors: Richard C. Chu, Michael J. Ellsworth, Jr., Egidio Marotta, Prabjit Singh
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Patent number: 7250222Abstract: A system for bonding layers (1) of different chemical compositions, such as bonding a thermal barrier layer to a metal substrate on a surface of a gas turbine component. A substrate (4) made either of a ceramic material or particularly of a metal super-alloy may be bonded to an outer layer (16) such as a ceramic by means of a fine-grained intermediate layer (7) bonded to the substrate (4), and a coarse-grained layer (10) bonded to the intermediate layer (7) to create a studded surface (9). The fine and coarse layers (7, 10) provide a transition between the substrate (4) and the outer layer (16) for improved bonding between them. The studded surface (9) may provide at least a 20% increase in bonding surface area for the outer layer (16). Additionally, a medium-grained layer (13) may be applied to the studded surface (9) before applying the outer layer(16).Type: GrantFiled: October 30, 2003Date of Patent: July 31, 2007Assignee: Siemens AktiengesellschaftInventors: Knut Halberstadt, Werner Stamm
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Patent number: 7250194Abstract: A method of making an article having both a polymeric substrate and a metallic spray deposited layer is disclosed. The coefficients of thermal expansion of the polymeric substrate and the metallic layer are preferably similar.Type: GrantFiled: April 7, 2005Date of Patent: July 31, 2007Assignee: GMIC, Corp.Inventors: Edmund Aversenti, Charles P. Covino
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Patent number: 7244512Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: GrantFiled: February 6, 2004Date of Patent: July 17, 2007Assignee: Ford Global Technologies, LLCInventors: John Ginder, Robert McCune, Franco Leonardi
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Patent number: 7229661Abstract: A method for fabricating and testing an article having a thermal-spray coating thereon. The method includes providing a substrate article having a surface, thermally spraying a coating material onto the surface of the substrate article, wherein a surface of contact between the coating material and the substrate article is a bondline, and nondestructively testing the coated article. Nondestructively testing includes generating an eddy current in the coated article, measuring the eddy current in the coated article, and evaluating a near-bondline region of the coated article located adjacent to the bondline using the measured eddy current.Type: GrantFiled: September 1, 2006Date of Patent: June 12, 2007Assignee: General Electric CompanyInventors: Patsy Augestine Ruzzo, Matthew Stewart, Anthony William Mellors
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Patent number: 7229700Abstract: A novel coating composition is provided for imparting corrosion and wear resistance to metal substrates. The novel coating composition is thermally applied and comprises an aluminum alloy mixed with a hard, inert matrix. The coating composition has found particular use in providing corrosion and wear resistance to metal seat rails used to secure aircrafts seats to the aircraft frame.Type: GrantFiled: October 26, 2004Date of Patent: June 12, 2007Assignee: BASF Catalysts, LLC.Inventors: Peter F. Ruggiero, Marc J. Froning
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Patent number: 7211177Abstract: Electrode at least comprising an electroconductive support of a titanium-palladium alloy, titanium, tantalum or compounds or alloys of titanium or of tantalum, an electrochemically active coating and an interlayer between the support and the electrochemically active coating, wherein the interlayer consists of titanium carbide and/or titanium boride and is applied to the support by flame or plasma spraying. Process for producing these electrodes and their use in an electrochemical cell for producing chlorine or chromic acid.Type: GrantFiled: December 31, 2002Date of Patent: May 1, 2007Assignees: Bayer Aktiengesellschaft, DeNora Elettrodi S.p.A.Inventors: Fritz Gestermann, Hans-Dieter Pinter, Gerd Speer, Peter Fabian, Robert Scannel
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Patent number: 7201945Abstract: A fiber product offering health-enhancing effects is obtained by causing a fibrous substrate to contain or be bonded with finely divided titanium powder through the process of impregnation with a water solution containing finely divided titanium powder, which is obtained by dissolving metallic titanium via the combustion gas produced by combusting a gaseous oxygen/hydrogen mixture in high-pressure water in a pressure-resistant tank.Type: GrantFiled: November 29, 2000Date of Patent: April 10, 2007Assignee: Phild Co., Ltd.Inventors: Yoshihiro Hirata, Yoshio Ueda, Hiroaki Takase, Kazuaki Suzuki
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Patent number: 7179539Abstract: An electric machine made from kinetically sprayed permanent magnet material and a binder material form a composite admixture having microstructure of permanent magnet material embedded in the binder material. The admixture has a permanent magnetic moment. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: GrantFiled: July 29, 2002Date of Patent: February 20, 2007Assignee: Ford Global Technologies, LLCInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Patent number: 7179507Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.Type: GrantFiled: April 28, 2005Date of Patent: February 20, 2007Assignee: Sulzer Metco (Canada) Inc.Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
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Patent number: 7150921Abstract: A bi-layer bond coating for use on metal alloy components exposed to hostile thermal and chemical environment, such as a gas turbine engine, and the method for applying such coatings. The preferred coatings include a bi-layer bond coat applied to the metal substrate using high velocity oxy-fuel (HVOF) thermal spraying. Bi-layer bond coatings in accordance with the invention consist of a dense first inner layer (such as iron, nickel or cobalt-based alloys) that provides oxidation protection to the metal substrate, and a second outer layer having controlled porosity that tends to promote roughness, mechanical compliance, and promotes adherence of the thermal barrier coating (TBC). Preferably, the outer, less dense layer of the bi-layer bond coat is formed from a mixture of metallic powder and polyester to adjust and control the porosity, but without sacrificing mechanical compliance.Type: GrantFiled: May 18, 2004Date of Patent: December 19, 2006Assignee: General Electric CompanyInventors: Warren Arthur Nelson, Jon Conrad Schaeffer, Sharon Trombly Swede, David Vincent Bucci, Joseph Debarro, Terry Howard Strout, Tyrone Robert Mortensen
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Patent number: 7125586Abstract: Disclosed is a process for applying a kinetic spray coating of powder particles onto a substrate covered in a plastic-type material without first removing the plastic-type material. In one use of the process a mask is used to enable a single kinetic spray pass to both remove the plastic covering and bind particles having average nominal diameters of from 60 to 250 microns to the underlying substrate. In another use of the process the particles have an average nominal diameter of from 250 to 1400 microns and the use of a mask is optional because the particles can penetrate the plastic material and bind directly to the substrate. The process finds special use in forming electrical connections or solderable pads anywhere along the length of a flexible circuit.Type: GrantFiled: March 30, 2004Date of Patent: October 24, 2006Assignee: Delphi Technologies, Inc.Inventors: Thomas Hubert Van Steenkiste, Daniel William Gorkiewicz, John R. Smith, Martin Stier, George Albert Drew
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Patent number: 7108893Abstract: Disclosed is a system and a method for simultaneously applying a kinetic spray coating and a thermal spray coating onto a substrate using a single application nozzle to produce a combined coating. The system may include a higher heat capacity gas heater to permit both the thermal spray and the kinetic spray. The method involves providing two populations of particles to the nozzle simultaneously wherein one population is thermally softened in the nozzle under the spray parameters and the other is not. The system increases the versatility of the spray nozzle and addresses several problems inherent in kinetic spray applied coatings.Type: GrantFiled: July 9, 2003Date of Patent: September 19, 2006Assignee: Delphi Technologies, Inc.Inventors: Thomas Hubert Van Steenkiste, Brian K Fuller
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Patent number: 7108894Abstract: Methods and apparatus for the deposition of a source material (10) are disclosed. An atomizer (12) renders a supply of source material (10) into many discrete particles. A force applicator (14) propels the particles in continuous, parallel streams of discrete particles. A collimator (16) controls the direction of flight of the particles in the stream prior to their deposition on a substrate (18). In an alternative embodiment of the invention, the viscosity of the particles may be controlled to enable complex depositions of non-conformal or three-dimensional surfaces. The invention also includes a wide variety of substrate treatments which may occur before, during or after deposition. In yet another embodiment of the invention, a virtual or cascade impactor may be employed to remove selected particles from the deposition stream.Type: GrantFiled: February 5, 2002Date of Patent: September 19, 2006Assignee: Optomec Design CompanyInventor: Michael J. Renn
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Patent number: 7105205Abstract: A thermal spray mixed with a substrate using a non-consumable cylindrical rotating tool. The process may be repeated to create a composite-like coating or material. The coating or material may be machine to improve surface quality.Type: GrantFiled: March 29, 2004Date of Patent: September 12, 2006Assignee: Research Foundation of the State of New YorkInventors: Clive Clayton, Herbert Herman, Henry White
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Patent number: 7094450Abstract: A method applying a thermal barrier coating to a metal substrate, or for repairing a thermal barrier coating previously applied by physical vapor deposition to an underlying aluminide diffusion coating that overlays the metal substrate. The aluminide diffusion coating is treated to make it more receptive to adherence of a plasma spray-applied overlay alloy bond coat layer. An overlay alloy bond coat material is then plasma sprayed on the treated aluminide diffusion coating to form an overlay alloy bond coat layer. A ceramic thermal barrier coating material is plasma sprayed on the overlay alloy bond coat layer to form the thermal barrier coating. In the repair embodiment of this method, the physical vapor deposition-applied thermal barrier coating is initially removed from the underlying aluminide diffusion coating.Type: GrantFiled: April 30, 2003Date of Patent: August 22, 2006Assignee: General Electric CompanyInventors: Bangalore Aswatha Nagaraj, Eva Zielonka Lanman, Deborah Anne Schorr, Thomas John Tomlinson, Raymond William Heidorn, David Allen Kastrup, Craig Douglas Young
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Patent number: 7081276Abstract: A method for thermally spraying a film on an inner face of a bore of a cylinder block. A pair of suction pipes generates a spiraling air current in the bore, creating an air flow toward the center of the bore. A spraying device sprays molten metal partaicles including fumes toward the inner face of the bore. The fumes are captured by the spiraling air current and removed from molten metal particles directing toward the inner face of the bore. Molten metal particles from which the fumes are removed form the thermally sprayed film on the inner face of the bore. High-quality thermally sprayed film scarcely containing fumes can be formed on the inner face of the bore.Type: GrantFiled: November 17, 2003Date of Patent: July 25, 2006Assignee: Toyota Jidosha Kabushiki KaishaInventors: Noritaka Miyamoto, Eiji Itakura
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Patent number: 7078073Abstract: According to an embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, is disclosed. The method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the base metal substrate removed. The portion of the base metal substrate removed has a thickness, ?t.Type: GrantFiled: November 13, 2003Date of Patent: July 18, 2006Assignee: General Electric CompanyInventors: Joseph D. Rigney, Ching-Pang Lee, Ramgopal Darolia
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Patent number: 7044191Abstract: The invention relates to a molten material processing device having an elongated thermal element like a heating element, a thermocouple, a sensor, a heatpipe and a cooling pipe which is characterised in that said elongated thermal element (2) is located in a recess (3) provided in a surface (6) of the molten material processing device (1), the recess (3), comprising a first portion (4) and a second portion (5), has a cross-section which is larger than a cross-section of the thermal element (2), so as to provide a clear space (7) between the thermal element (2) and the surface (6) of the processing device (1), the clear space (7) which is limited by the first portion (4) and the thermal element (2) is filled by a thermally sprayed material (8) and the second portion (5), which is adapted to the cross-section of the thermal element (2), partially surrounds and directly contacts same.Type: GrantFiled: May 25, 2001Date of Patent: May 16, 2006Assignee: Mold-Masters LimitedInventors: Jonathon Fischer, Dan Zuraw
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Patent number: 7026016Abstract: The method of fabricating free standing objects using thermal spraying, preferably of a metal, in the following process. A wire mesh is formed into a three dimensional shape of the desired finished product and the shaped mesh is then thermally sprayed with a coating material to substantially cover the visible portions of the mesh. The preferred coating material is metal.Type: GrantFiled: January 2, 2004Date of Patent: April 11, 2006Inventor: Eric C. Bauer
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Patent number: 7008674Abstract: A thermal barrier coating for an underlying metal substrate of articles that operate at, or are exposed to, high temperatures, as well as being exposed to environmental contaminant compositions. This coating comprises an optional inner layer nearest to the underlying metal substrate comprising a non-alumina ceramic thermal barrier coating material in an amount up to 100%, and an outer layer having an exposed surface and comprising at least about 50% of a non-alumina ceramic thermal barrier coating material and alumina in an amount up to about 50% and sufficient to protect the thermal barrier coating at least partially against environmental contaminants that become deposited on the exposed surface. This coating can be used to provide a thermally protected article having a metal substrate and optionally a bond coat layer adjacent to and overlaying the metal substrate.Type: GrantFiled: November 18, 2004Date of Patent: March 7, 2006Assignee: General Electric CompanyInventors: Bangalore Aswatha Nagaraj, Brett Allen Boutwell, Robert George Baur
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Patent number: 7005404Abstract: A substrate having a catalytic surface thereon characterized as a coating of metal oxide and noble metal particles in the nominal diameter size distribution range of <3 microns, and more particularly <1 micron, is produced by thermal spraying a mixture of large size particles (e.g., in a nominal size distribution range of >10 micrometers) of hydroxides, carbonates or nitrates of the metals: cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium particles; and hydroxides, carbonates or nitrates of the noble metals: ruthenium, rhodium, palladium, silver, iridium, platinum and gold onto the substrate. The coating adheres to the surface and provides desirable catalyst properties.Type: GrantFiled: July 24, 2001Date of Patent: February 28, 2006Assignee: Honda Motor Co., Ltd.Inventor: Ting He
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Patent number: 7001670Abstract: The invention relates to a wear protection layer for piston rings in internal combustion engines consisting essentially of chromium carbides, wolfram carbide, chromium and nickel. The wear protection layer is formed from a mixture of powders in which the first powder consists of at least the alloy components chromium carbide, chromium and nickel, in the form of an agglomerated and sintered powder, and which has not been subjected to any secondary heat treatment that would make the powder brittle, such as plasma refinement, the carbides in the powder having an average diameter of essentially not more than 3 ?m. A second powder, also in the form of an agglomerated and sintered powder, contains wolfram carbide and is applied to at least one peripheral surface of the piston rings by thermal injection, so that two distinctive coating areas are produced in the wear protection layer. A first area, predominantly rich in chromium, and a second area, mainly rich in wolfram carbide are formed.Type: GrantFiled: November 17, 2001Date of Patent: February 21, 2006Assignee: Federal-Mogul Burscheid GmbHInventor: Christian Herbst-Dederichs
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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: 6923241Abstract: Method and apparatus for controlling stresses in a spray form process makes use of one dimensional modeling in which characteristics of a geometrical point are quantified by iterative detection, such as taking a surface temperature reading using a pyrometer. This temperature information is used in a one dimensional simulation to predict characteristics for a column from the point down through a spray-formed article to an interface with a substrate. The modeling technique can used with a plurality of geometrical points to model the whole article, and the one dimensional simulation can be integrated with robotic spray-forming controls to minimize residual stress in the spray-formed article.Type: GrantFiled: November 27, 2001Date of Patent: August 2, 2005Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, Samir Samir, Chijoke Mgbokwere, Mark Lusk
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Patent number: 6924249Abstract: Disclosed is a method for direct application of a catalyst to a substrate for treatment of atmospheric pollution including ozone. The method includes applying a catalytic metal to a substrate utilizing a thermal spray process. The process can be utilized to apply a base metal such as copper to a substrate and the base metal becomes the catalytically active oxide during and following application to the substrate. This system replaces a multi-step process within a single step process to provide a catalytically active surface that can be utilized to reduce ground level ozone and other atmospheric pollutants.Type: GrantFiled: October 2, 2002Date of Patent: August 2, 2005Assignee: Delphi Technologies, Inc.Inventors: John R. Smith, Michel Farid Sultan, Ming-Cheng Wu, Zhibo Zhao, Bryan A. Gillispie
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Patent number: 6904950Abstract: Method and apparatus for controlling a spray-forming process incorporating time, temperature, and transformation dependent stress relief techniques involves the manipulation of both temperature and time for strategic phase changes that result in a specific and planned volumetric increase. This manipulation is made based on controlling ongoing spray parameters to spray-form an article having a mixed-phase and interspersed makeup of metallic phases that minimizes residual stress in the article.Type: GrantFiled: November 27, 2001Date of Patent: June 14, 2005Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, Samir Samir, Chijoke Mgbokwere, Mark Lusk
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Patent number: 6902768Abstract: The cylinder walls of light metal engine blocks are thermally spray coated with a ferrous-based coating including aluminum using an HVOF device. A ferrous-based wire is fed to the HVOF device to locate a tip end of the wire in a high temperature zone of the device. Jet flows of oxygen and gaseous fuel are fed to the high temperature zone and are combusted to generate heat to melt the tip end. The oxygen is oversupplied in relation to the gaseous fuel. The excess oxygen reacts with and burns a fraction of the ferrous-based feed wire in an exothermic reaction to generate substantial supplemental heat to the HVOF device. The molten/combusted metal is sprayed by the device onto the walls of the cylinder by the jet flow of gases.Type: GrantFiled: February 13, 2002Date of Patent: June 7, 2005Assignee: General Motors CorporationInventors: John Robert Smith, David Rudolph Sigler, Richard Earl Teets, Larry Edward Byrnes, Martin Stephen Kramer
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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: 6897921Abstract: A reflecting member having roughness is formed on a surface above a substrate and transferred onto a film with an adhesive layer interposed therebetween. For example, a removable organic insulating layer having roughness on a surface thereof is formed above a glass substrate, and then a metal layer is formed on the rough surface of the organic insulating layer, thus forming a reflecting member. The reflecting member is then transferred onto the film with and adhesive layer interposed therebetween.Type: GrantFiled: October 5, 2001Date of Patent: May 24, 2005Assignee: Kyodo Printing Co., Ltd.Inventors: Tadahiro Furukawa, Kimikazu Okayasu, Hisashi Sato, Tatsuhiko Murai
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Patent number: 6887530Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.Type: GrantFiled: June 7, 2002Date of Patent: May 3, 2005Assignee: Sulzer Metco (Canada) Inc.Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
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Method and arrangement for implementing heat treatment during the execution of spray-form techniques
Patent number: 6883581Abstract: A method for implementing post-heat treatment during spray forming to achieve stress control in the manufacture of a spray formed metallic tool involves applying a metallic spray-forming material onto a mold substrate and causing substantially homogenous metallic phase transformations from the austenite phase, for example, via manipulation of either or both of the substrate temperature and the spray forming cell environment temperature.Type: GrantFiled: November 27, 2001Date of Patent: April 26, 2005Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, Samir Samir, Chijoke Mgbokwere, Mark Lusk -
Patent number: 6884516Abstract: It is to propose an internal member for a plasma treating vessel having excellent resistances to chemical corrosion and plasma erosion under an environment containing a halogen gas and an advantageous method of producing the same, which is a member formed by covering a surface of a substrate with a multilayer composite layer consisting of a metal coating formed as an undercoat, Al2O3 film formed on the undercoat as a middle layer and Y2O3 sprayed coating formed on the middle layer as a top coat.Type: GrantFiled: May 21, 2004Date of Patent: April 26, 2005Assignees: Tocalo Co., Ltd., Tokyo Electron Co., Ltd.Inventors: Yoshio Harada, Junichi Takeuchi, Tatsuya Hamaguchi, Nobuyuki Nagayama, Kouji Mitsuhashi
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Patent number: 6878412Abstract: A process of fabricating a corrosion and erosion resistant component. In one embodiment, the process entails applying one or more corrosion resistant materials onto a pre-formed, sacrificial core and then enclosing this first material and the core with a surrounding capsule. Any space within the capsule is then substantially filled with a second material, after which the capsule is sealed and treated to cause the second material to densify and to metallurgically bond to the first material. Thereafter, the core material and capsule are removed via chemical and/or mechanical processes to yield a component with a shape that approximates the space that existed between the capsule and the first material, and with an outer surface that reflects the shape of the outer surface of the core and the inner surface of the capsule.Type: GrantFiled: March 26, 2001Date of Patent: April 12, 2005Assignee: Bodycote IMT, Inc.Inventors: John C. Hebeisen, Stephen J. Mashl
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Patent number: 6875476Abstract: A method for masking at least one turbine engine component wherein the method includes providing at least one masking member, securing each masking member to the at least one turbine engine component, and applying a metal coating to the at least one turbine engine component.Type: GrantFiled: January 15, 2003Date of Patent: April 5, 2005Assignee: General Electric CompanyInventors: Philip Robert Hawtin, Michael Smith