Oxide-containing Component Patents (Class 428/632)
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Patent number: 6528189Abstract: In order to form a novel article of manufacture, a nickel or cobalt-based superalloy substrate is covered with a protective system resistant to thermal, corrosive and erosive attack. A bonding layer is disposed on the substrate and an anchoring layer on the bonding layer. The anchoring layer is formed as a nitride compound. The nitride compound is aluminum nitride in particular. A ceramic coating is disposed on the anchoring layer. The anchoring layer prevents transmission of diffusion active elements through the anchoring layer to the thermal barrier layer, reduces oxidation of layers therebelow and provides for good heat transmission therethrough.Type: GrantFiled: December 14, 1998Date of Patent: March 4, 2003Assignee: Siemens AktiengesellschaftInventor: Wolfram Beele
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Patent number: 6528180Abstract: A method for metallizing integrated circuits is disclosed. In one aspect, an integrated circuit is metallized by depositing liner material on a substrate followed by one or more metal layers. The liner material is selected from the group of tantalum (Ta), tantalum nitride (TaN), niobium (Nb), niobium nitride (NbN), vanadium (V), vanadium nitride (VN), and combinations thereof. The liner material is preferably conformably deposited on the substrate using physical vapor deposition (PVD). The one or more metal layers are deposited on the barrier layer using chemical vapor deposition (CVD), physical vapor deposition (PVD), or a combination of both CVD and PVD.Type: GrantFiled: May 23, 2000Date of Patent: March 4, 2003Assignee: Applied Materials, Inc.Inventors: Wei Ti Lee, Ted Guo, Gongda Yao
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Patent number: 6524723Abstract: Disclosed is a copper foil—for printed circuit boards—which is especially excellent in soft etching property and also superior in such properties as heat discoloration resistance, rust-proofing and solder-ability. The copper foil for printed circuit boards comprising a first layer formed by applying 12 to 50 mg/m2 of a sulfur-contained zinc alloy containing 0.1 to 2.5 percent by weight of sulfur on the surface on at least one side of the copper foil and a second layer formed of a chromate layer on the first layer by applying 0.5 to 2.5 mg/m2 of chromium and, if necessary, 1.5 to 6 mg/m2 of phosphorus.Type: GrantFiled: April 12, 2001Date of Patent: February 25, 2003Assignee: Fukuda Metal Foil & Powder Co., Ltd.Inventors: Masaru Hirose, Masasto Takami
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Patent number: 6521356Abstract: An environmentally resistant coating for improving the oxidation resistance of a niobium-based refractory metal intermetallic composite (Nb-based RMIC) at high temperatures, the environmentally resistant coating comprising silicon, titanium, chromium, and niobium. The invention includes a turbine system having turbine components comprising at least one Nb-based RMIC, the environmentally resistant coating disposed on a surface of the Nb-based RMIC, and a thermal barrier coating disposed on an outer surface of the environmentally resistant coating. Methods of making a turbine component having the environmentally resistant coating and coating a Nb-based RMIC substrate with the environmentally resistant coating are also disclosed.Type: GrantFiled: February 2, 2001Date of Patent: February 18, 2003Assignee: General Electric CompanyInventors: Ji-Cheng Zhao, Melvin Robert Jackson, Bernard Patrick Bewlay
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Publication number: 20030027013Abstract: A thermal insulating ceramic layer for use on metal alloy components exposed to hostile thermal and chemical environment, such as a gas turbine engine used to generate electricity. The preferred thermal barrier layer is formed using dense vertical cracking and formed of zirconia that is partially stabilized by yttria in a preferred amount of less than 4 weight percent and about 1 weight percent Hafnia. The ceramic layer is optimized to protect the underlying superalloy component from erosion, chipping, and handling, while reducing the cost of the protective layer. An alternative method of preparing the thermal barrier coating uses electron beam physical vapor deposition.Type: ApplicationFiled: July 31, 2001Publication date: February 6, 2003Inventors: Jon C. Schaeffer, Robert W. Bruce
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Publication number: 20030027012Abstract: A coating system having a low thermal conductivity, and a method by which the low thermal conductivity of the coating system is maintained through the development of cracks within a thermal-insulating layer of the coating system. The thermal-insulating layer is a mixture of two or more materials with different coefficients of thermal expansion (CTE). The materials of the thermal-insulating layer are selected and combined so that a low thermal conductivity is maintained for the coating system as the result of cracks developing and propagating from interfaces between the materials when the coating system is subjected to heating and cooling cycles.Type: ApplicationFiled: August 3, 2001Publication date: February 6, 2003Inventors: Irene Spitsberg, Hongyu Wang
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Patent number: 6514629Abstract: An article such as a gas turbine blade or vane has a superalloy substrate, and a coating system deposited on the substrate. The coating system includes a protective layer overlying the substrate, and, optionally, a ceramic thermal barrier coating layer overlying the bond coat. The protective layer has an uppermost layer with a composition including platinum, aluminum, and, in atom percent, from about 0.14 to about 2.8 percent hafnium and from about 2.7 to about 7.0 percent silicon, with the atomic ratio of silicon:hafnium being from about 1.7:1 to about 5.6:1.Type: GrantFiled: December 15, 1998Date of Patent: February 4, 2003Assignee: General Electric CompanyInventors: Joseph D. Rigney, Ramgopal Darolia, William S. Walston
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Patent number: 6511762Abstract: A cooling system for cooling of the flow path surface region of an engine component used in a gas turbine engine and a method for making a system for cooling of the flow path surface region of an engine component used in a gas turbine engine. The method comprises the steps of channeling apertures in a substrate to a diameter of about 0.0005″ to about 0.02″ to allow passage of cooling fluid from a cooling fluid source; applying a bond coat of about 0.0005″ to about 0.005″ in thickness to the substrate such that the bond coat partially fills the channels; applying a porous inner TBC layer of at least about 0.01″ in thickness to the bond coat, such that the TBC fills the channels; applying an intermediate ceramic layer that is more dense than the inner TBC layer on top of the porous TBC; applying an outer TBC layer over the intermediate layer; and, passing cooling fluid from a cooling fluid source through the channel into the porous TBC.Type: GrantFiled: November 6, 2000Date of Patent: January 28, 2003Assignee: General Electric CompanyInventors: Ching-Pang Lee, Robert Edward Schafrik, Ramgopal Darolia
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Publication number: 20030017358Abstract: The coated device contains a coating for use with corrosive environments at high temperatures. The device has a bond coat consisting essentially of, by weight percent, 0 to 5 carbon, 20 to 40 chromium, 0 to 5 nickel, 0 to 5 iron, 2 to 25 total molybdenum plus tungsten, 0 to 3 silicon 0 to 3 boron and balance cobalt and essential impurities to provide sulfidation resistance at high temperatures. A zirconia-base ceramic coating covers the bond coat for heat resistance. Optionally, a boride or carbide coating covers the zirconia for additional resistance to erosion.Type: ApplicationFiled: March 19, 2001Publication date: January 23, 2003Inventor: Harold Haruhisa Fukubayashi
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Patent number: 6506509Abstract: The present invention relates to composite electroless coatings with varying densities of codeposited particles in the plated layer along the surface of the substrate where said variation of densities is directed by the angle of rotation of the substrate during the coating process.Type: GrantFiled: August 5, 1999Date of Patent: January 14, 2003Assignee: Surface Technology, Inc.Inventors: Michael David Feldstein, Thomas Stephen Lancsek
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Publication number: 20030008167Abstract: 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: ApplicationFiled: March 21, 2002Publication date: January 9, 2003Inventors: Michael Loch, Gerard Barbezat
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Publication number: 20030008166Abstract: A method for forming a thermal barrier coating system on a turbine engine component includes forming a bondcoat on the turbine engine component and depositing a thermal barrier coating so as to overlie the bondcoat. The bondcoat is formed by thermally co-spraying first and second distinct alloy powders on the turbine engine component forming an oxidation-resistant region, and thermally spraying a third alloy powder on the oxidation-resistant region to form a bonding region.Type: ApplicationFiled: October 30, 2001Publication date: January 9, 2003Inventors: Anthony Mark Thompson, Wayne Charles Hasz
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Patent number: 6500565Abstract: The present invention provides a corrosion resistant resin coating excellent in corrosion resistance, weather resistance and chemical resistance, mechanically tough and strong and having high heat resistance temperature. A steel tube optionally having a copper layer is formed. Then, a zinc or zinc/nickel plating layer is formed on the outer circumferential surface of the steel tube, and a chromate film comprising a trivalent chromium compound is formed on the zinc or zinc/nickel plating layer. At least one layer of a kind of resin selected from the group consisting of polyvinyl fluoride, polyvinylidene fluoride, polypropylene, polyethylene and polyamide resins is formed, as required, through a primer. Sufficiently satisfactory results are obtained in corrosion resistance test.Type: GrantFiled: August 17, 1998Date of Patent: December 31, 2002Assignee: Usui Kokusai Sangyo Kaisha LimitedInventor: Masayoshi Usui
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Publication number: 20020197502Abstract: A barrier coating is disclosed, containing about 15 atom % to about 95 atom % chromium; and about 5 atom % to about 60 atom % of at least one of rhenium, tungsten, and ruthenium. Nickel, cobalt, iron, and aluminum may also be present. The barrier coating can be disposed between a metal substrate (e.g., a superalloy) and an oxidation-resistant coating, preventing the substantial diffusion of various elements at elevated service temperatures. A ceramic overcoat (e.g., based on zirconia) can be applied over the oxidation-resistant coating. Related methods for applying protective coatings to metal substrates are also described.Type: ApplicationFiled: June 11, 2001Publication date: December 26, 2002Inventors: Ji-Cheng Zhao, Melvin Robert Jackson
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Patent number: 6497968Abstract: 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: GrantFiled: February 26, 2001Date of Patent: December 24, 2002Assignee: General Electric CompanyInventors: Ji-Cheng Zhao, Bernard Patrick Bewlay, Melvin Robert Jackson
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Publication number: 20020192496Abstract: A method for producing a turbine airfoil that is coated with a beta phase, high aluminum content coating, such as substantially stoichiometric NiAl, and which has a surface finish suitable for application of a ceramic topcoat. The method involves impacting the coating with preselected particles of a preselected size so that the brittle coating is not adversely affected by chipping or breakage. The impacting produces a surface finish of 120 micro-inches or better so that a ceramic thermal barrier layer can be applied over the coating. The preferred method of improving the surface finish utilizes steel balls having a diameter of about 0.033″ and a peening intensity of no greater than about 6A.Type: ApplicationFiled: May 3, 2002Publication date: December 19, 2002Inventors: Richard J. Grylls, Yuk-Chiu Lau
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Publication number: 20020192488Abstract: To provide a composite material member for semiconductor device, an insulated semiconductor device and non-insulated semiconductor device using the composite material member, which are effective for obtaining a semiconductor device that alleviates thermal stress or thermal strain occurring during production or operation, has no possibilities of deformation, degeneration and rupture of each member, and is highly reliably and inexpensive. The composite material member for semiconductor device is characterized by being a composite metal plate with particles composed of cuprous oxide dispersed in a copper matrix, in which a surface of the composite metal plate is covered with a metal layer, and a copper layer with thickness of 0.5 &mgr;m or larger exists in an interface formed by the composite metal plate and the metal layer.Type: ApplicationFiled: February 27, 2002Publication date: December 19, 2002Inventors: Yasutoshi Kurihara, Yasuo Kondo, Takumi Ueno, Toshiaki Morita, Kenji Koyama, Takashi Suzumura, Kazuhiko Nakagawa, Kunihiro Fukuda
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Patent number: 6495271Abstract: A method for producing a spallation-resistant aluminum oxide layer on the surface of a superalloy article is described. An aluminum oxide layer is produced, typically under tensile stress, by chemical vapor deposition at low temperatures on a metal aluminide layer that has been deposited on the surface of the article. The aluminum oxide layer is then heated to induce cracking therein, which imparts spallation-resistance thereto. If desired, a thermal barrier layer may be deposited on the aluminum oxide layer.Type: GrantFiled: September 1, 2000Date of Patent: December 17, 2002Assignee: General Electric CompanyInventor: Himanshu Bachubhai Vakil
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Patent number: 6492034Abstract: In a heat shield (1), in particular for combustion chambers and for thermal fluid flow machines, the heat shield consists of a feltlike material (3) composed of compressed and sintered intermetallic fibers. Advantageously, the intermetallic fibers consist of an iron based or nickel based intermetallic phase.Type: GrantFiled: November 12, 1998Date of Patent: December 10, 2002Assignee: AlstomInventors: Mohamed Nazmy, Martin Scheu, Markus Staubli
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Patent number: 6492040Abstract: To make stress corrosion cracking caused by precipitation of a &bgr; layer (Mg2Al3) in a welding part (5) or in the periphery of the welding part (5) hard to occur. An apparatus body (1) and a header (3) formed of an aluminum alloy with precipitation of magnesium suppressed by standardized heat treatment are assembled and welded, and natural gas containing mercury is subjected to heat exchanging. There are provided with backing metal (4) disposed on the back of the inner wall surface of one header (3) prior to standardized heat treatment and placed in contact with the other apparatus body (1) at the time of assembling and welding, a welding part (5) formed by being assembled and welded using first welding metal containing magnesium at percent content not less than 2.Type: GrantFiled: June 27, 2001Date of Patent: December 10, 2002Assignee: Kabushiki Kaisha Kobe Seiko ShoInventors: Koji Noishiki, Kenichirou Mitsuhashi, Shuhei Natani, Masahiro Gotou
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Patent number: 6492038Abstract: A thermal barrier coating (TBC) and method for forming the coating on a component intended for use in a hostile environment. The coating and method are particularly directed to inhibiting sintering, grain coarsening/growth and pore redistribution in the coating during high temperature excursions by providing limited amounts of extremely fine carbide-based and/or nitride-based precipitates preferably formed at defects and pores at and between the grain boundaries of the TBC microstructure. The precipitates pin the TBC grain boundaries and pores during high temperature excursions, with the effect that the TBC microstructure is thermally stabilized. A coating containing the carbides and/or nitrides can be formed using a physical vapor deposition technique in an atmosphere that contains carbon and/or nitride gases or compounds thereof, or by evaporating a source material that contains carbon, carbon-containing compounds, carbides and/or nitrides.Type: GrantFiled: November 27, 2000Date of Patent: December 10, 2002Assignee: General Electric CompanyInventors: Joseph David Rigney, Ramgopal Darolia
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Patent number: 6485845Abstract: A thermal barrier coating (TBC) system and method for forming the TBC system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The TBC system exhibits improved spallation resistance as a result of having a bond coat formed to contain a dispersion of oxide particles in its outer surface region. A method for preferentially entrapping oxide particles in a bond coat entails depositing the oxide particles on the surface of the component prior to forming the bond coat, which may be a diffusion aluminide or an aluminized overlay coating. Deposition of the bond coat causes the oxide particles to become dispersed in the outer surface region of the bond coat. A particular feature of this invention is the ability to preferentially entrap oxides of elements that are not present in the bond coat or a substrate region of the component on which the bond coat is formed.Type: GrantFiled: January 24, 2000Date of Patent: November 26, 2002Assignee: General Electric CompanyInventors: Roger D. Wustman, Jeffrey A. Conner, Jonathan P. Clarke, Timothy L. Norris, William E. Brummett, II, Thomas E. Mantkowski
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Patent number: 6485844Abstract: A thermal barrier coating for nickel based superalloy articles such as turbine engine vanes and blades that are exposed to high temperature gas is disclosed. The coating includes a columnar grained ceramic layer applied to a platinum modified Ni3Al gamma prime phase bond coat having a high purity alumina scale. The preferred composition of the bond coat is 5 to 16% by weight of aluminum, 5 to 25% by weight of platinum with the balance, at least 50% by weight, nickel. A method for making the bond coat is also disclosed.Type: GrantFiled: April 4, 2000Date of Patent: November 26, 2002Assignee: Honeywell International, Inc.Inventors: Thomas E. Strangman, Derek Raybould
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Publication number: 20020172799Abstract: A device having an improved thermal barrier coating (46) and a process for manufacturing the same. A support structure (28) for retaining a ceramic insulating material (46) on a substrate (16) is formed by the deposition of a support structure material through a patterned masking material (14). The support structure can define cells into which the ceramic insulating material is deposited following removal of the masking material. The masking material may be patterned by known photolithographic techniques (22,24) or by laser etching (48).Type: ApplicationFiled: May 16, 2001Publication date: November 21, 2002Applicant: Siemens Westinghouse Power CorporationInventor: Ramesh Subramanian
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Publication number: 20020172838Abstract: A thermal barrier coating (TBC) for a component intended for use in a hostile environment, such as the superalloy turbine, combustor and augmentor components of a gas turbine engine. The TBC is formed of zirconia that is partially stabilized with yttria (YSZ), preferably not more than 3 weight percent yttria, and to which one or more additional metal oxides are alloyed to increase crystallographic defects and lattice strains in the TBC grains and/or form precipitates of zirconia and/or compound(s) of zirconia and/or yttria and the additional metal oxide(s), the inclusion of which reduces the thermal conductivity of the YSZ to levels lower than conventional 6-8% YSZ. Improvements are particularly contemplated for TBC having a columnar grain structure, such as those deposited by EBPVD and other PVD techniques.Type: ApplicationFiled: April 12, 2001Publication date: November 21, 2002Inventors: Joseph David Rigney, Ramgopal Darolia
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Publication number: 20020172837Abstract: A device operable in a temperature environment in excess of about 1000° C. is provided. The device comprises a substrate and a ceramic thermal barrier layer deposited on at least a portion of the substrate. The layer is formed with a ternary or pseudoternary oxide having a pyrochlore or perovskite structure and a fugative material and having pores or other voluminous defects. The thermal barrier layer advantageously is abradable.Type: ApplicationFiled: May 13, 2002Publication date: November 21, 2002Inventors: David B. Allen, Ramesh Subramanian, Wolfram Beele
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Patent number: 6482537Abstract: A thermal barrier coating for superalloy articles such as turbine engine vanes and blades that are exposed to high temperature gas is disclosed. The coating includes a columnar grained ceramic layer applied to an aluminide or MCrAlY bond coat by electron beam physical vapor deposition. The ceramic layer is comprised a plurality of layers of zirconia stabilized with 20 percent yttria and the interfaces between the layers are decorated with particles selected from a group consisting of Ta2O5 and alumina. Though not essential to the invention a layer of tetragonal zirconia may be deposited both under and over the ceramic coat. An improved electron physical beam vapor deposition process for applying this ceramic layer is also disclosed.Type: GrantFiled: March 24, 2000Date of Patent: November 19, 2002Assignee: Honeywell International, Inc.Inventors: Thomas E. Strangman, Derek Raybould
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Publication number: 20020168539Abstract: An article is coated with a multi-layer coating having scratch resistance, abrasion resistance, corrosion resistance and improved chemical and oxidation resistance. The coating comprises an electroplated layer or layers on the article surface, a refractory metal or refractory metal alloy strike layer on the electroplated layer or layers, and a protective layer containing a refractory metal oxide or refractory metal alloy oxide on the strike layer.Type: ApplicationFiled: May 11, 2001Publication date: November 14, 2002Inventors: Patrick B. Jonte, James S. Lipe, Guocun Chen
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Publication number: 20020155313Abstract: The present invention comprises a method of manufacturing a brazed body. The method comprises forming a multi-layer assembly comprising: a first material capable of forming a first oxide and having a melting temperature higher than 660° C.; a first reducing metal adjacent the first material, the reducing metal capable of reducing at least a portion of the first oxide on the first material a braze adjacent to the reducing metal; and a second material adjacent the braze, the second material comprising a material having a melting temperature higher than 660° C. The method then comprises creating a vacuum around the assembly, and heating the assembly to melt the reducing metal and the braze. The assembly is then subject to cooling to thereby form the brazed body.Type: ApplicationFiled: February 20, 2001Publication date: October 24, 2002Applicant: 3M Innovative Properties CompanyInventor: Gary M. Palmgren
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Publication number: 20020155314Abstract: A surface-treated steel sheet includes a steel sheet, an Al—Zn-base alloy plating layer formed on the steel sheet, a chemical conversion film provided on the alloy plating layer, and a concentric layer of a Cr compound that is formed on the alloy plating layer of the chemical conversion film. The surface-treated steel sheet may include a steel sheet, an zinc-base plating layer formed on the steel sheet, and a film that contains chromium and calcium and that is formed on the zinc-base plating layer.Type: ApplicationFiled: December 17, 2001Publication date: October 24, 2002Inventors: Takafumi Yamaji, Kenji Morita, Akira Matsuzaki, Masaaki Yamashita, Etsuo Hamada
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Publication number: 20020150785Abstract: An article is coated with a multi-layer decorative and protective coating having the appearance of stainless steel. The coating comprises one or more electroplated layers on the surface of said article and vapor deposited on the electroplated layers a refractory metal nitride, refractory metal alloy nitride, or reaction products of refractory metal or refractory metal alloy, nitrogen and oxygen wherein the nitrogen content of the refractory metal nitride, refractory metal alloy nitride or reaction products of refractory metal or refractory metal alloy, nitrogen and oxygen is from about 3 to about 22 atomic percent.Type: ApplicationFiled: April 5, 2001Publication date: October 17, 2002Inventor: Guocun Chen
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Publication number: 20020150784Abstract: An article is coated with a multi-layer decorative and protective coating having the appearance of stainless steel. The coating comprises one or more electroplated layers on the surface of said article and vapor deposited on the electroplated layers a stack layer containing layers of refractory metal or metal alloy alternating with layers containing refractory metal nitrogen containing compounds and refractory metal alloy nitrogen containing compounds wherein the nitrogen content of the refractory metal nitrogen containing compounds and refractory metal alloy nitrogen containing compounds is from about 3 to about 22 atomic percent.Type: ApplicationFiled: April 5, 2001Publication date: October 17, 2002Inventor: Guocun Chen
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Publication number: 20020146586Abstract: An article is coated with a multi-layer decorative and protective coating having the appearance of stainless steel. The coating comprises one or more electroplated layers on the surface of said article and vapor deposited on the electroplated layers a color layer comprised of the reaction products of refractory metal or refractory metal alloy, nitrogen and oxygen wherein the total nitrogen and oxygen content is from about 4 to about 32 atomic percent with the nitrogen content being at least about 3 atomic percent.Type: ApplicationFiled: April 5, 2001Publication date: October 10, 2002Inventor: Guocun Chen
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Publication number: 20020146587Abstract: A nickel-base superalloy substrate includes a surface region having an integrated aluminum content of from about 18 to about 24 percent by weight and an integrated platinum content of from about 18 to about 45 percent by weight, with the balance components of the substrate. The substrate is preferably a single-crystal advanced superalloy selected for use at high temperatures. The substrate may optionally have a ceramic layer deposited over the platinum-aluminide region, to produce a thermal barrier coating system. The platinum-aluminide region is produced by diffusing platinum into the substrate surface, and thereafter diffusing aluminum into the substrate surface.Type: ApplicationFiled: April 2, 2002Publication date: October 10, 2002Inventor: Jon C. Schaeffer
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Patent number: 6461746Abstract: A nickel-base superalloy article has a surface protective layer comprising nickel, from about 20 to about 35 weight percent aluminum, and from about 0.5 to about 10 weight percent rhenium. The protective layer, which is preferably an overlay coating of the beta (&bgr;) phase NiAl form, is formed by depositing nickel, aluminum, rhenium, and modifying elements onto the substrate surface. A ceramic layer may be deposited overlying the protective layer.Type: GrantFiled: April 24, 2000Date of Patent: October 8, 2002Assignee: General Electric CompanyInventors: Ramgopal Darolia, Joseph D. Rigney
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Patent number: 6458473Abstract: A thermal barrier coating system and a method for forming the coating system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The method is particularly directed to a thermal barrier coating system that includes a thermal insulating ceramic layer and a diffusion aluminide bond coat on which an aluminum oxide scale is grown to protect the underlying surface of the component and to chemically bond the ceramic layer. The bond coat is formed to contain an additive metal of platinum, palladium, rhodium, chromium and/or silicon, and an additive element of yttrium and/or zirconium, with possible additions of hafnium. The bond coat may be formed by codepositing aluminum with the active element, or by depositing the additive metal and active element on the surface of the component, and then aluminizing to form the diffusion aluminide bond coat.Type: GrantFiled: January 21, 1997Date of Patent: October 1, 2002Assignee: General Electric CompanyInventors: Jeffrey A. Conner, Bangalore A. Nagaraj, Joseph A. Heaney, III, Nripendra N. Das, Patricia A. Zomcik, David J. Wortman, David V. Rigney, Jon C. Schaeffer
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Patent number: 6455174Abstract: A magnetic recording medium comprises, on a substrate, a recording auxiliary layer, a recording holding layer, recording control layer, and a recording layer. The recording layer is constructed by using a ferri-magnetic material having perpendicular magnetization. The data can be recorded at a super high density by using the recording and reproducing head of the present invention, because the recording layer has the perpendicular magnetization. The disappearance of data, which would be otherwise caused by the thermomagnetic relaxation phenomenon, is suppressed after recording the data, because the recording layer has large coercive force at the room temperature. The data, which is recorded at the super high density on the magnetic recording medium, can be reproduced by using a magnetic resistance element carried on the recording and reproducing head.Type: GrantFiled: November 3, 1999Date of Patent: September 24, 2002Assignee: Hitachi Maxell, Ltd.Inventors: Hiroki Takao, Yuji Yamazaki, Susumu Imai, Hiroyuki Awano, Katsusuke Shimazaki
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Publication number: 20020132132Abstract: A process is disclosed for forming an improved aluminide coating which includes one or more oxygen active elements. A metallic substrate is coated with an overlay coating, such as an MCrAl coating, including one or more oxygen active elements such as yttrium, hafnium and silicon, by a conventional overlay process such as low pressure plasma spray. A metal, preferably a Series VIII transition metal such as platinum, is applied to the substrate, for example by electroplating. The substrate is then aluminized, for example by chemical vapor deposition, and is preferably heat treated. A ceramic thermal barrier may also be applied. The present invention provides an active element containing aluminide coating having a more consistent composition and having improved durability, either as a standalone coating or as a bond coat for a subsequently-applied thermal barrier coating.Type: ApplicationFiled: December 12, 2000Publication date: September 19, 2002Inventors: Sudhangshu Bose, Walter E. Olson, David N. Duhl
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Patent number: 6451434Abstract: A glass laminate comprising a glass substrate, an oxide layer as a first layer formed on the glass substrate, and at least one multilayer (B) and at least one layer (C) which are laminated in this order or alternately on the first layer, wherein the first layer comprises a zinc oxide film (A) containing Al in a ratio of Al/(Al+Zn) of from 15 to 50 at %, the layer (B) comprises Ag as the main component, the layer (C) is composed of at least one member selected from the group consisting of oxides, nitrides, carbides and double compounds thereof, and the total number of the first layer, the layer(s) (B) and the layer(s) (C) is 2n+1 (wherein n is a positive integer).Type: GrantFiled: December 20, 1999Date of Patent: September 17, 2002Assignee: Asahi Glass Company, LimitedInventors: Junichi Ebisawa, Nobutaka Aomine, Satoshi Takeda, Kazuyoshi Noda, Daniel Decroupet
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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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Publication number: 20020114971Abstract: A chemically processed steel sheet comprises a steel base coated with an Al-Si alloy plating layer, whose Si content is preferably adjusted to 5-13 mass % as a whole and to 7-80 mass % at a surface, and a converted layer generated on the surface of the plating layer. The converted layer contains both of soluble and scarcely-soluble compounds. The soluble compound such as a manganese oxide or hydroxide or a valve metal fluoride is once dissolved to water in an atmosphere and then re-precipitated as scarcely-soluble compounds at defective parts of the converted layer. The scarcely-soluble compounds act as a barrier for corrosion-prevention of a base steel. Due to the re-precipitation, i.e. self-repairing faculty, excellent corrosion resistance of the converted layer is still maintained even after defects are introduced therein during plastic deformation of the steel sheet.Type: ApplicationFiled: November 6, 2001Publication date: August 22, 2002Applicant: Nisshin Steel Co., Ltd.Inventors: Masaya Yamamoto, Mitsuo Asabuki, Shigeyasu Morikawa, Shinya Furukawa, Hirofumi Taketsu
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Publication number: 20020114970Abstract: An article is coated with a multi-layer coating having the appearance of nickel. The coating comprises one or more electroplated layers on the surface of said article and vapor deposited on the electroplated layers a refractory metal or metal alloy nitride where the nitrogen content of said nitride is from about 6 to about 45 atomic percent.Type: ApplicationFiled: December 21, 2000Publication date: August 22, 2002Inventors: Guocun Chen, Stephen R. Moysan
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Patent number: 6436545Abstract: A joint body according to the invention is strong for a heat cycle and generates no local cracks. The joint body has the following features. An end portion of the metal member and the ceramic member are connected via a metal connection portion. The metal connection portion has a metallized layer formed on the ceramic member and a brazing connection portion interposing at least between the metallized layer and an end portion of the metal member. A melt point of a brazing member constructing the brazing connection portion is lower than that of a brazing member constructing the metallized layer.Type: GrantFiled: January 25, 2000Date of Patent: August 20, 2002Assignee: NGK Insulators, Ltd.Inventors: Nobuyuki Tanahashi, Tomoyuki Fujii, Tsuneaki Ohashi
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Patent number: 6432558Abstract: A semiconductor ceramic device comprises a body composed of a semiconductor ceramic having a positive resistance-temperature coefficient primarily composed of barium titanate and electrodes provided on the body, in which the resistance-temperature coefficient is 9%/° C. or more, resistivity is 3.5 ∩·cm or less, and withstand voltage is 50 V/mm or more. As the semiconductor ceramic forming the body provided in a thermistor having positive resistance-temperature characteristics, a semiconductor ceramic having a positive resistance-temperature coefficient is used, in which the semiconductor ceramic has an average particle diameter of about 7 to 12 &mgr;m and comprises barium titanate as a major component and sodium in an amount of about 70 ppm or less on a weight basis.Type: GrantFiled: August 8, 2000Date of Patent: August 13, 2002Assignee: Murata Manufacturing Co. Ltd.Inventors: Yasuhiro Nabika, Tetsukazu Okamoto, Toshiharu Hirota, Yoshitaka Nagao
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Publication number: 20020098345Abstract: A chromium-free agent for treating metallic surface comprising the following (i)-(iv):Type: ApplicationFiled: April 22, 1999Publication date: July 25, 2002Inventors: HIROAKI KAMO, YASUNARI HOTTA, TOSHIYUKI SHIMIZU, HISAO ODASHIMA
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Publication number: 20020094447Abstract: A method for improving the thermal fatigue life of a thermal barrier coating (TBC) deposited on an aluminide bond coat through a process by which the surface morphology of the aluminide bond coat is modified to eliminate or at least reduce oxidation and oxidation-induced convolutions at the alumina-bond coat interface, as explained more fully below. The bond coat is deposited to have generally columnar grains and grain boundary ridges at its surface, and is then peened at an intensity sufficient to flatten at least some of the grain boundary ridges, but insufficient to cause recrystallization of the bond coat when later heated, such as during deposition of the thermal barrier coating. In so doing, the original surface texture of the bond coat is altered to be smoother where the grain boundaries meet the bond coat surface, thereby yielding a smoother bond coat surface where the critical alumina-bond coat interface will exist following oxidation of the bond coat.Type: ApplicationFiled: January 16, 2002Publication date: July 18, 2002Inventor: Irene Theodor Spitsberg
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Publication number: 20020090529Abstract: A new processed steel sheet comprises a steel base coated with a Zn or its alloy plating layer and a converted layer, which contains both of at least an insoluble or scarcely-soluble metal compound and at least a soluble metal compound. The insoluble or scarcely-soluble compound may be one ore more of valve metal oxides or hydroxides, and the soluble compound may be one or more of valve metal fluorides. The converted layer may be also composed of one ore more of complex compounds of Mn and Ti. The insoluble or scarcely-soluble compound acts as a barrier for insulation of a steel base from an atmosphere, while the soluble compound exhibits a self-repairing faculty to repair defective parts of the converted layer. Due to the converted layer, the processed steel sheet is remarkably improved in corrosion resistance, without presence of chromium compounds which would put harmful influences on the environment.Type: ApplicationFiled: November 9, 2001Publication date: July 11, 2002Applicant: Nisshin Steel Co., Ltd.Inventors: Kouichiro Ueda, Shigeyasu Morikawa, Tadashi Nakano, Yasumi Ariyoshi, Keiji Izumi, Masanori Matsuno, Hirofumi Taketsu
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Publication number: 20020090528Abstract: The present invention provides a corrosion resistant resin coating structure excellent in corrosion resistance, weather resistance and chemical resistance, mechanically tough and strong and having high heat resistance temperature.Type: ApplicationFiled: August 17, 1998Publication date: July 11, 2002Inventor: MASAYOSHI USUI
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Publication number: 20020090527Abstract: A method for providing a protective coating on a metal-based substrate is disclosed. The method involves the application of an aluminum-rich mixture to the substrate to form a discontinuous layer of aluminum-rich particles, followed by the application of a second coating over the discontinuous layer of aluminum-rich particles. Aluminum diffuses from the aluminum-rich layer into the substrate, and into any bond coat layer which is subsequently applied. Related articles are also described.Type: ApplicationFiled: January 4, 2002Publication date: July 11, 2002Inventors: Anthony Mark Thompson, Dennis Michael Gray, Melvin Robert Jackson
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Patent number: 6416882Abstract: An article that is particularly well suited for use as a gas turbine engine component has a ceramic thermal insulation layer overlaying a bonding layer. The bonding layer is an alloy comprising iron, cobalt and/or nickel and either: the following group 1 elements (by weight percent): Chromium: 3% to 50% Aluminum: 3% to 20% Yttrium and/or a rare-earth element: 0.01% to 0.5% Lanthanum: 0.1% to 10% Hafnium: 0 to 10% Magnesium: 0 to 10% Silicon: 0 to 2%, or the following group 2 elements (by weight percent): Chromium: 3% to 50% Aluminum: 3% to 20% Yttrium and/or a rare-earth element: 0 to 0.5% Lanthanum: 0.1% to 10% Hafnium: 0.1% to 10% Magnesium: 0 to 10% Silicon: 0 to 2%.Type: GrantFiled: May 1, 2000Date of Patent: July 9, 2002Assignee: Siemens AktiengesellschaftInventors: Wolfram Beele, Beate Heimberg