Plural Oxides Patents (Class 428/633)
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Patent number: 7364802Abstract: Ceramic compositions comprising at least about 91 mole % zirconia and up to about 9 mole % of a stabilizer component comprising a first metal oxide having selected from the group consisting of yttria, calcia, ceria, scandia, magnesia, india and mixtures thereof. This stabilizer component further comprises a second metal oxide of a trivalent metal atom selected from the group consisting of lanthana, gadolinia, neodymia, samaria, dysprosia, erbia, ytterbia, and mixtures thereof. These ceramic compositions are useful in preparing thermal barrier coatings having reduced thermal conductivity for the metal substrate of articles that operate at, or are exposed to, high temperatures.Type: GrantFiled: December 30, 2003Date of Patent: April 29, 2008Assignee: General Electric CompanyInventors: Irene Spitsberg, Venkat Subramanian Venkataramani, Brett Allen Boutwell, Mark Daniel Gorman, Robert William Bruce
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Patent number: 7364798Abstract: 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: March 7, 2005Date of Patent: April 29, 2008Assignees: Tocalo Co., Ltd., Tokyo Electron LimitedInventors: Yoshio Harada, Junichi Takeuchi, Nobuyuki Nagayama, Kouji Mitsuhashi
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Patent number: 7354663Abstract: A thermal barrier coating enabling to prevent peeling of layer in a high temperature use and still having a high thermal barrier effect, a turbine part coated by this thermal barrier coating and a gas turbine comprising this turbine part are provided. The thermal barrier coating comprises a base material 21 of high temperature heat resistant alloy and a ceramics layer 23 formed on the base material 21. The ceramics layer 23 comprises ZrO2 added with Yb2O3 as stabilizer and is laminated on the base material via a bond coat layer 22 laminated as a metallic bond layer. A plurality of cracks 23A are preferably introduced in the ceramics layer 23. The turbine part is constructed having its surface coated with the above thermal barrier coating.Type: GrantFiled: April 2, 2004Date of Patent: April 8, 2008Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Taiji Torigoe, Kazutaka Mori, Sunao Aoki, Kouji Takahashi, Minoru Ohara
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Patent number: 7354660Abstract: Alloy compositions which are resistant to metal dusting corrosion are provided by the present invention. Also provided are methods for preventing metal dusting on metal surfaces exposed to carbon supersaturated environments. The alloy compositions include an alloy (PQR), and a multi-layer oxide film on the surface of the alloy (PQR). The alloy (PQR) includes a metal (P) selected from the group consisting of Fe, Ni, Co, and mixtures thereof, an alloying metal (Q) comprising Cr, Mn, and either Al, Si, or Al/Si, and an alloying element (R). When the alloying metal (Q) includes Al, the multi-layer oxide film on the surface of the alloy includes at least three oxide layers. When the alloying metal (Q) includes Si, the multi-layer oxide film on the surface of the alloy (PQR) includes at least four oxide layers. When the alloying metal (Q) includes Al and Si, the multi-layer oxide film on the surface of the alloy (PQR) includes at least three oxide layers.Type: GrantFiled: May 10, 2005Date of Patent: April 8, 2008Assignee: ExxonMobil Research and Engineering CompanyInventors: ChangMin Chun, Trikur A. Ramanarayanan
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Zinc hot dip galvanized steel plate excellent in press formability and method for production thereof
Patent number: 7338718Abstract: A hot-dip galvanized steel sheet includes a plating layer substantially composed of the ? phase and an oxide layer disposed on a surface of the plating layer. The oxide layer has an average thickness of 10 nm or more and includes a Zn-based oxide layer and an Al-based oxide layer. A method for producing the hot-dip galvanized steel sheet includes a hot-dip galvanization step, a temper rolling step, and an oxidation step.Type: GrantFiled: October 17, 2003Date of Patent: March 4, 2008Assignee: JFE Steel CorporationInventors: Shoichiro Taira, Masaki Tada, Yoshiharu Sugimoto, Masayasu Nagoshi, Takashi Kawano, Etsuo Hamada, Satoru Ando, Shinji Ootsuka, Masaaki Yamashita -
Patent number: 7311981Abstract: A gas turbine part comprises a superalloy metal substrate, a bonding underlayer formed on the substrate and comprising an intermetallic compound of aluminum, nickel, and platinum, and a ceramic outer layer anchored on the alumina film formed on the bonding underlayer. The bonding underlayer essentially comprises an Ni—Pt—Al ternary system constituted by an aluminum-enriched ?-NiPt type structure, in particular an Ni—Pt—Al ternary system having a composition NizPtyAlx in which z, y, and x are such that 0.05?z?0.40, 0.30?y?0.60, and 0.15?x?0.40.Type: GrantFiled: October 28, 2004Date of Patent: December 25, 2007Assignee: SNECMAInventors: Bertrand Saint Ramond, Manuel Silva, John Nicholls, Maxime Carlin
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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: 7291408Abstract: A ceramic material having particular utility as a thermal insulating or thermal barrier coating on metallic substrates is provided. The ceramic material broadly comprises at least one oxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia. The at least one oxide has a formula A2O3 where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Tb, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof. The present invention also broadly relates to an article having a metal substrate and a thermal barrier coating as discussed above.Type: GrantFiled: August 12, 2003Date of Patent: November 6, 2007Assignee: United Technologies CorporationInventors: David A. Litton, Nicholas E. Ulion, Mladen F. Trubelja, Michael J. Maloney, Sunil Govinda Warrier
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Patent number: 7291816Abstract: A method for making a transparent electrothermal body includes: a) plating ITO (indium tin oxide) onto a surface of a transparent substrate to form an ITO film, and b) printing a conducting material onto a surface of the ITO film to form two connecting portions each electrically connected to the ITO film, thereby forming a transparent electrothermal body. Thus, the transparent electrothermal body includes a circuit made of ITO material having greater transparency to form a conducting film that allows passage of the electric current, thereby enhancing the transparency of the electrothermal body, and thereby increasing the versatility of the electrothermal body.Type: GrantFiled: May 17, 2004Date of Patent: November 6, 2007Inventor: Shu-Lien Chen
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Patent number: 7288328Abstract: An article for use in hostile thermal environments, such as a component of a gas turbine engine. The article includes a nickel-base superalloy substrate that is prone to formation of a deleterious secondary reaction zone (SRZ), and an overlay coating having a predominantly gamma prime-phase nickel aluminide (Ni3Al) composition suitable for use as an environmental coating, including a bond coat for a thermal barrier coating. The coating comprises a chromium-containing nickel aluminide intermetallic overlay coating of predominantly the gamma prime phase, in which aluminum is present in the coating in an amount approximately equal to the aluminum content of the superalloy substrate so as to inhibit diffusion of aluminum from the overlay coating into the superalloy substrate.Type: GrantFiled: October 29, 2004Date of Patent: October 30, 2007Assignee: General Electric CompanyInventors: Ramgopal Darolia, William Scott Walston
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Patent number: 7267889Abstract: The present invention provides a sprayable composition comprising a ceramic particulate including albite, illite, and quart, and a metallic composition, including nickel, chromium, iron, and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The present invention further provides an abradable coating formed on a metal substrate according to a method comprising the step of depositing the abradable coating on the metal substrate by thermal spraying of a sprayable composition comprising a ceramic particulate including albite, illite, and quartz, and a metallic composition, including nickel, chromium, iron and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The abradable coating may be applied to a metal substrate such as steel, nickel-based alloys, and titanium.Type: GrantFiled: October 1, 2002Date of Patent: September 11, 2007Assignee: Sulzer Metco (Canada) Inc.Inventors: Karel Hajmrle, Anthony Peter Chilkowich
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Patent number: 7264888Abstract: An overlay coating for articles used in hostile thermal environments. The coating has a predominantly gamma prime-phase nickel aluminide (Ni3Al) composition suitable for use as an environmental coating and as a bond coat for a thermal barrier coating. The coating has a composition of, by weight, at least 6% to about 15% aluminum, about 2% to about 5% chromium, optionally one or more reactive elements in individual or combined amounts of up to 4%, optionally up to 2% silicon, optionally up to 60% of at least one platinum group metal, and the balance essentially nickel. A thermal-insulating ceramic layer may be deposited on the coating.Type: GrantFiled: October 29, 2004Date of Patent: September 4, 2007Assignee: General Electric CompanyInventors: Ramgopal Darolia, Joseph David Rigney, William Scott Walston
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Patent number: 7189465Abstract: Provided is a chromium-free metal surface treatment agent excellent in rust inhibitive performance which can be used in a surface treatment of metal products, in particular, galvanized metal products. The metal surface treatment agent consists essentially of a siliceous binder solution comprising water and/or alcohol as a solvent, and the concentration of the silica component is 8 to 25% by weight. In particular, a metal surface treatment agent containing an alcoholic solution of alkoxysilane oligomer having a weight averaged molecular weight of 1000 to 10000, which is obtained by hydrolyzed condensation polymerization of alkoxysilane, can suppress the occurrence of white rusting for a long time. It is preferred that 3 to 25 parts by weight of a dispersed nano-sized titanium dioxide powder having an average primary particle size of not more than 70 nm, per 100 parts by weight of the silica component be suspended in the siliceous binder solution.Type: GrantFiled: August 13, 2004Date of Patent: March 13, 2007Assignee: Hoden Seimitsu Kako Kenkyusho Co., Ltd.Inventors: Yasuhiko Endo, Tomio Sakai
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Patent number: 7186466Abstract: A thermal barrier coating composition is provided. The composition has a base oxide, a primary stabilizer, and at least two additional cationic oxide dopants. Preferably, a pair of group A and group B defect cluster-promoting oxides is used in conjunction with the base and primary stabilizer oxides. The new thermal barrier coating is found to have significantly lower thermal conductivity and better sintering resistance. In preferred embodiments, the base oxide is selected from zirconia and hafnia. The group A and group B cluster-promoting oxide dopants preferably are selected such that the group A dopant has a smaller cationic radius than the primary stabilizer oxide, and so that the primary stabilizer oxide has a small cationic radius than that of the group B dopant.Type: GrantFiled: November 17, 2005Date of Patent: March 6, 2007Assignees: Ohio Aerospace Institute, The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Dongming Zhu, Robert A. Miller
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Patent number: 7172820Abstract: A strengthened bond coat for improving the adherence of a thermal barrier coating to an underlying metal substrate to resist spallation without degrading oxidation resistance of the bond coat. The bond coat comprises a bond coating material selected from the group consisting of overlay alloy coating materials, aluminide diffusion coating materials and combinations thereof. Particles comprising a substantially insoluble bond coat strengthening compound and having a relatively fine particle size of about 2 microns or less are dispersed within at least the upper portion of the bond coat in an amount sufficient to impart strengthening to the bond coat, and thus limit ratcheting or rumpling thereof.Type: GrantFiled: October 13, 2005Date of Patent: February 6, 2007Assignee: General Electric CompanyInventors: Ramgopal Darolia, Joseph David Rigney, Gillion Herman Marijnissen, Eric Richard Irma Carolus Vergeldt, Annejan Bernard Kloosterman
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Patent number: 7169478Abstract: Multinary alloys, in particular for use as coatings, if appropriate in combination with other types of layers, for components which are exposed to high temperatures and corrosive gases. The alloys are of the general form: Al—Ni—Ru-M, where at least one B2 phase is present, the aluminum content being in the range from 26–60 atomic percent and where M may be one or more metals and/or semimetals selected from the group consisting of: precious metal, transition metal, rare earths, semimetal. Multinary alloys of this type are very stable with respect to oxidation, have a low thermal conductivity and in particular have similar coefficients of thermal expansion to superalloys, which are usually used as substrates for protective coatings of this type in gas turbine components.Type: GrantFiled: July 16, 2004Date of Patent: January 30, 2007Assignee: Alstom Technology Ltd.Inventors: Anton Kaiser, Valery Shklover, Walter Steurer, Ivan Victor Vjunitsky
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Patent number: 7147934Abstract: 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 soluble and scarcely-soluble compounds. The soluble compound, such as a manganese oxide or hydroxide, or a valve metal fluoride, is once dissolved into 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: GrantFiled: April 22, 2004Date of Patent: December 12, 2006Assignee: Nisshin Steel Co., Ltd.Inventors: Masaya Yamamoto, Mitsuo Asabuki, Shigeyasu Morikawa, Shinya Furukawa, Hirofumi Taketsu
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Patent number: 7105236Abstract: The subject matter of the invention is a thermal-insulating material having an essentially magnetoplumbitic crystal structure, a metal substrate having a adhesive layer and a thermal-insulating layer made of the thermal-insulating material on its surface, and a process for coating metal substrates with the thermal-insulating material.Type: GrantFiled: July 19, 2005Date of Patent: September 12, 2006Assignee: Deutsches Zentrum fur Luft-und Raumfahrt e. V.Inventors: Bilge Saruhan-Brings, Uwe Schulz, Claus Jürgen Kröder
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Patent number: 7074497Abstract: A coated steel sheet having a coated layer on surfaces of a steel sheet of a composition containing not less than 0.1 mass % and under 3 mass % of Al, wherein a following condition A or B is met: A: An AlN precipitate layer exists on a matrix side near an interface between said steel sheet and said coated layer B: Oxide of Al exists in said matrix right under said surfaces of said steel sheet.Type: GrantFiled: February 26, 2003Date of Patent: July 11, 2006Assignee: JFE Steel CorporationInventors: Yoshitsugu Suzuki, Kazuaki Kyono
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Patent number: 7056853Abstract: An oxide ceramic material is provided to contain aluminum oxide as a principal component, and at least one selected from A and B shown below as an auxiliary component: A: niobium oxide and copper oxide B: copper oxide, titanium oxide, and silver oxide. With this, it is possible to provide an oxide ceramic material having sinterability at a low temperature and a high heat conductivity, as well as a ceramic substrate, a ceramic laminate device, and a power amplifier module employing the same.Type: GrantFiled: January 21, 2004Date of Patent: June 6, 2006Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Osamu Inoue, Kenji Harada, Kojiro Okuyama
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Patent number: 7048993Abstract: A method to produce a distortion-free asymmetrical low-temperature co-fired ceramic structure comprising at least one layer of glass-containing internal constraining tape and at least one layer of glass-containing primary tape wherein the internal constraining tape and the primary tape are laminated to form an asymmetrical laminate and wherein a release layer is deposited on at least one surface of the laminate forming an assembly, wherein the surface is opposite the position of greatest asymmetry of the laminated layers and wherein the assembly is thermally processed producing a structure exhibiting an interactive suppression of x,y shrinkage.Type: GrantFiled: May 21, 2004Date of Patent: May 23, 2006Assignee: E. I. du Pont de Nemours and CompanyInventors: Carl B. Wang, Kenneth Warren Hang, Christopher R. Needes
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Patent number: 7037596Abstract: This invention relates to a catalytic composition which comprises a coating of a coating material on a support and is obtainable by applying the coating material, comprising (1) a polycondensate of at least one hydrolysable organosilane and also, if desired, one or more compounds of glass-forming elements, and (2) particles of one or more transition metal oxides, the weight ratio of transition metal oxide particles to polycondensate being from 10:1 to 1:10, to the support and subjecting the applied coating material to thermal treatment. The invention also relates to a process for preparing this catalytic composition and to its use for the purpose of deodorizing or oxidizing organic components or carbon.Type: GrantFiled: April 5, 2000Date of Patent: May 2, 2006Assignee: Leibniz-Institut Fuer Neue Materialien Gemeinnuetzige GmbHInventors: Thomas Benthien, Stefan Faber, Gerhard Jonschker, Stefan Sepeur, Helmut Schmidt, Philipp Stoessel
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Patent number: 7037603Abstract: The invention is directed to a material and a method of producing the material that is unaffected by the low-temperature degradation, humidity-enhanced phase transformation typical of yttria-stabilized zirconia in general, as well as of yttria-stabilized tetragonal zirconia polycrystalline ceramic (Y-TZP). Because of the high fracture toughness and high mechanical strength, this class of materials is widely used, including as implants, such as for the packaging material for small implantable neural-muscular sensors and stimulators. The destructive phase transformation is eliminated by converting the surface to stable cubic or T-prime zirconia by post-densification thermal treatment in a cation-rich milieu.Type: GrantFiled: May 25, 2004Date of Patent: May 2, 2006Assignee: Alfred E. Mann Foundation for Scientific ResearchInventor: Brian J. Lasater
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Patent number: 6991860Abstract: Interference pigment flakes and foils are provided which have color shifting properties. The pigment flakes can have a symmetrical coating structure on opposing sides of a reflector layer, can have an asymmetrical coating structure with all of the layers on one side of the reflector layer, or can be formed with encapsulating coatings around a core reflector layer. The coating structure of the flakes and foils includes a reflector layer, a dielectric layer on the reflector layer, and a titanium-containing absorber layer on the dielectric layer. The pigment flakes and foils exhibit a discrete color shift so as to have a first color at a first angle of incident light or viewing and a second color different from the first color at a second angle of incident light or viewing. The pigment flakes can be interspersed into liquid media such as paints or inks to produce colorant compositions for subsequent application to objects or papers.Type: GrantFiled: April 14, 2003Date of Patent: January 31, 2006Assignee: JDS Uniphase CorporationInventors: Roger W. Phillips, Charlotte R. LeGallee, Paul T. Kohlmann, Vladimir Raksha, Alberto Argoitia
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Patent number: 6982126Abstract: A thermal barrier coating (TBC) for a component intended for use in a hostile thermal environment. The TBC has an interior region and an outer surface region on and contacting the interior region. Both regions are formed of a ceramic material, with the interior region having a lower thermal conductivity than zirconia partially stabilized by about seven weight percent yttria. The interior region constitutes more than half of the thickness of the TBC, and the outer surface region constitutes less than half of the thickness of the TBC. The TBC has a columnar microstructure whereby the interior region and the outer surface region comprise columns of their ceramic materials. The outer surface region is more erosion and impact resistant than the interior region at least in part as a result of the columns thereof being more closely spaced than the columns of the interior region.Type: GrantFiled: November 26, 2003Date of Patent: January 3, 2006Assignee: General Electric CompanyInventors: Ramgopal Darolia, Irene Spitsberg, Brett Allen Rohrer Boutwell, Mark Daniel Gorman, Curtis Alan Johnson, Venkat Subramaniam Venkataramani
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Patent number: 6979498Abstract: A strengthened bond coat for improving the adherence of a thermal barrier coating to an underlying metal substrate to resist spallation without degrading oxidation resistance of the bond coat. The bond coat comprises a bond coating material selected from the group consisting of overlay alloy coating materials, aluminide diffusion coating materials and combinations thereof. Particles comprising a substantially insoluble bond coat strengthening compound and having a relatively fine particle size of about 2 microns or less are dispersed within at least the upper portion of the bond coat in an amount sufficient to impart strengthening to the bond coat, and thus limit ratcheting or rumpling thereof.Type: GrantFiled: November 25, 2003Date of Patent: December 27, 2005Assignee: General Electric CompanyInventors: Ramgopal Darolia, Joseph David Rigney, Gillion Herman Marijnissen, Eric Richard Irma Carolus Vergeldt, Annejan Bernard Kloosterman
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Patent number: 6960395Abstract: Ceramic compositions comprising at least about 91 mole % zirconia and up to about 9 mole % of a stabilizer component comprising a first metal oxide having selected from the group consisting of yttria, calcia, ceria, scandia, magnesia, india and mixtures thereof. This stabilizer component further comprises a second metal oxide of a trivalent metal atom selected from the group consisting of lanthana, gadolinia, neodymia, samaria, dysprosium, and mixtures thereof and a third metal oxide of a trivalent metal atom selected from the group consisting of erbia, ytterbia and mixtures thereof. These ceramic compositions are useful in preparing thermal barrier coatings having reduced thermal conductivity for the metal substrate of articles that operate at, or are exposed to, high temperatures.Type: GrantFiled: December 30, 2003Date of Patent: November 1, 2005Assignee: General Electric CompanyInventors: Irene Spitsberg, Venkat Subramanian Venkataramani, Brett Allen Boutwell, Mark Daniel Gorman
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Patent number: 6953620Abstract: A coating system and a method for its manufacture are provided. An electrically conductive base coat and a porous overcoat lying over the base coat are arranged on a ceramic substrate. At least one additional deposited layer is arranged on the base coat in such a way that the additional layer is formed in the pores of the porous overcoat adjacent to the base coat. The additional layer is deposited either by currentless or electrolytic deposition. For electrolytic deposition of the additional layer, the ceramic substrate sintered with the base coat and the overcoat is submerged in an electrolytic bath and the base coat is connected as a cathode. The currentless deposition takes place from a solution of the metal to be deposited with the addition of a reducing agent.Type: GrantFiled: July 18, 2001Date of Patent: October 11, 2005Assignee: Robert Bosch GmbHInventors: Jens Stefan Schneider, Frank Stanglmeier, Bernd Schumann
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Patent number: 6939603Abstract: A component (10) having a thermal barrier coating (14) exhibiting an improved resistance to thermal shock. A plurality of stress relieving cracks (22) are formed at the free surface (24) of the thermal barrier coating as a result of the expansion of an inclusion (20) having a higher coefficient of thermal expansion than that of the surrounding matrix material (16). The inclusions function as crack initiators during the fabrication process as well as crack arrestors preventing the propagation of the cracks farther into the matrix material. The inclusion material may be selected to have an evaporation temperature that is less than the peak matrix material processing temperature, wherein the inclusion material will evaporate to leave a plurality of voids (30). In one embodiment, a superalloy substrate (12) is coated with a ceramic thermal barrier coating material having a plurality of spherical polymer inclusions disposed below its free surface.Type: GrantFiled: March 1, 2002Date of Patent: September 6, 2005Assignee: Siemens Westinghouse Power CorporationInventor: Matthias Oechsner
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Patent number: 6933060Abstract: A device (10) is made, having a ceramic thermal barrier coating layer (16) characterized by a microstructure having gaps (18) with a sintering inhibiting material (22) disposed on the columns (20) within the gaps (18). The sintering resistant material (22) is stable over the range of operating temperatures of the device (10), is not soluble with the underlying ceramic layer (16) and is applied by a process that is not an electron beam physical vapor deposition process. The sintering inhibiting material (22) has a morphology adapted to improve the functionality of the sintering inhibiting material (22), characterized as continuous, nodule, rivulet, grain, crack, flake and combinations thereof and being disposed within at least some of the vertical and horizontal gaps.Type: GrantFiled: May 30, 2002Date of Patent: August 23, 2005Assignee: Siemens Westinghouse Power CorporationInventors: Ramesh Subramanian, Brig B. Seth
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Patent number: 6933061Abstract: 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 inner layer nearest to the underlying metal substrate comprising a ceramic thermal barrier coating material having a melting point of at least about 2000° F. (1093° C.), as well as a thermally glazed outer layer having an exposed surface and a thickness up to 0.4 mils (about 10 microns) and sufficient to at least partially protect the thermal barrier coating against environmental contaminants that become deposited on the exposed surface, and comprising a thermally glazeable coating material having a melting point of at least about 2000° F. (1093° C.) in an amount up to 100%. This coating can be used to provide a thermally protected article having a metal substrate and optionally a bond coated layer adjacent to and overlaying the metal substrate.Type: GrantFiled: December 12, 2002Date of Patent: August 23, 2005Assignee: General Electric CompanyInventors: Bangalore Aswatha Nagaraj, Brett Allen Boutwell, Todd Jay Rockstroh, Wilbur Douglas Scheidt
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Patent number: 6919035Abstract: Metal oxide coated substrates are disclosed comprising a three dimensional substrate having a coating of metal oxide on at least a portion of all three dimensions thereof and having a polymeric inner core, produced by a unique process having particular applicability to the manufacture of tin oxide coated three dimensional substrates. Certain novel coated substrates, such as flakes, spheres and porous substrates are disclosed. The coated substrates are useful in polymers, catalysis, heating and shielding applications.Type: GrantFiled: May 18, 2001Date of Patent: July 19, 2005Assignee: Ensci Inc.Inventor: Thomas J. Clough
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Patent number: 6916551Abstract: A thermal barrier coating material can prevent spall-off from occurring during operation at high temperatures and has a high heat insulating effect. A turbine parts and a gas turbine that are protected with the thermal barrier coating material are also provided. The thermal barrier coating material of the present invention comprises a ceramic layer 23, which is formed on a high temperature heat-resistant alloy base 21 to protect the base 21 from high temperatures, the ceramic layer 23 being applied via a bonding coat layer 22 provided as a metal bonding layer and is made of ZrO2 with Er2O3 added thereto as a stabilizing agent. The turbine parts and the gas turbine of the present invention are coated with the thermal barrier coating material on the surfaces thereof.Type: GrantFiled: October 21, 2002Date of Patent: July 12, 2005Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Taiji Torigoe, Sunao Aoki, Kazutaka Mori, Ikuo Okada, Kouji Takahashi
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Patent number: 6908692Abstract: An electrically conductive wire coated with a curable coating composition that forms a cured coating having a high partial discharge resitance and good mechanical properties. A process for coating an electrically conductive wire with a curable coating composition and curing the coating composition to form a coating having high partial discharge resistance and good mechanical properties.Type: GrantFiled: March 1, 2000Date of Patent: June 21, 2005Assignee: E. I. du Pont de Nemours and CompanyInventors: Frank-Rainer Böhm, Gerhard Kiessling, Manfred Oppermann, Heinz Schindler
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Patent number: 6893750Abstract: 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: December 12, 2002Date of Patent: May 17, 2005Assignee: General Electric CompanyInventors: Bangalore Aswatha Nagaraj, Brett Allen Boutwell, Robert George Baur
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Patent number: 6890668Abstract: A coating material for a component intended for use in a hostile thermal environment. The coating material has a cubic microstructure and consists essentially of either zirconia stabilized by dysprosia, erbia, gadolinium oxide, neodymia, samarium oxide or ytterbia, or hafnia stabilized by dysprosia, gadolinium oxide, samarium oxide, yttria or ytterbia. Up to five weight percent yttria may be added to the coating material.Type: GrantFiled: August 30, 2002Date of Patent: May 10, 2005Assignee: General Electric CompanyInventors: Robert William Bruce, Glen Alfred Slack
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Patent number: 6887589Abstract: A beta-phase NiAl overlay coating containing a dispersion of ceramic particles and a process for depositing the overlay coating. If the coating is used to adhere a thermal barrier coating (TBC), the TBC exhibits improved spallation resistance as a result of the dispersion of ceramic particles having a dispersion-strengthening effect on the overlay coating. The overlay coating contains at least one reactive element and is deposited so that the some of the reactive element deposits as the ceramic particles dispersed in the overlay coating.Type: GrantFiled: April 18, 2003Date of Patent: May 3, 2005Assignee: General Electric CompanyInventors: Ramgopal Darolia, Joseph David Rigney, William Scott Walston, Jeffrey Allan Pfaendtner, Brett Allen Rohrer Boutwell, Irene Spitsberg, James Anthony Ruud
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Patent number: 6887588Abstract: An article protected by a thermal barrier coating system includes a substrate having a substrate surface, and a thermal barrier coating system overlying the substrate. The thermal barrier coating system has a thermal barrier coating formed of a thermal barrier coating material arranged as a plurality of columnar grains extending generally perpendicular to the substrate surface and having grain surfaces. A sintering inhibitor is within the columnar grains, either uniformly distributed or concentrated at the grain surfaces. The sintering inhibitor is lanthanum oxide, chromium oxide, and/or yttrium chromate, mixtures thereof, or mixtures thereof with aluminum oxide.Type: GrantFiled: September 21, 2001Date of Patent: May 3, 2005Assignee: General Electric CompanyInventors: John Frederick Ackerman, Venkat Subramaniam Venkataramani, Irene Spitsberg, Ramgopal Darolia
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Patent number: 6887595Abstract: A thermal barrier coatings for the underlying substrate of articles that operate at, or are exposed to, high temperatures. The thermal barrier coating includes a zirconia-containing upper layer wherein the zirconia is stabilized in the cubic crystalline phase to reduce the thermal conductivity of the coating. The thermal barrier coating further includes a zirconia-containing lower layer stabilized in the tetragonal crystalline phase that increases the adherence of the upper layer to the bond coat layer that overlies the substrate of the article to improve the resistance of the coating to spallation.Type: GrantFiled: December 30, 2003Date of Patent: May 3, 2005Assignee: General Electric CompanyInventors: Ramgopal Darolia, Irene Spitsberg, Brett Allen Boutwell, Mark Daniel Gorman, Robert William Bruce
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Patent number: 6887587Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.Type: GrantFiled: June 10, 2003Date of Patent: May 3, 2005Assignee: United Technologies CorporationInventors: William P. Allen, William A. Veronesi, Robert J. Hall, Michael J. Maloney, John W. Appleby, Douglas C. Hague, Abdus Khan
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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: 6861157Abstract: Articles for use in a high-temperature, oxidative environment, methods for manufacturing such articles, and a material system for protecting articles in such an environment are provided where, for example, one article comprises a substrate and a protective layer disposed over the substrate, the protective layer comprising at least about 60 atomic percent of a metal selected from the group consisting of platinum (Pt), palladium (Pd), rhodium (Rh), osmium (Os), iridium (Ir), and mixtures thereof.Type: GrantFiled: March 18, 2002Date of Patent: March 1, 2005Assignee: General Electric CompanyInventors: Ji-Cheng Zhao, Melvin Robert Jackson
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Patent number: 6858334Abstract: Zirconia-containing ceramic compositions having a c/a ratio of the zirconia lattice in the range of from about 1.005 to about 1.016. These compositions comprise a stabilizing amount up to about 10 mole % of the composition of a stabilizer component which comprises: (1) a first metal oxide selected from the group consisting of yttria, calcia, ceria, scandia, magnesia, india and mixtures thereof in an amount of from about 1.5 to about 6 mole % of the composition of; (2) a second metal oxide selected from the group consisting of lanthana, neodymia and mixtures thereof in an amount of from about 0.5 to about 4 mole % of the composition; and (3) optionally ytterbia in an amount of from about 0.5 to about 4 mole % of the composition. These compositions further comprise hafnia in an amount of from about 0.5 to about 15 mole % of the composition; and optionally tantala in an amount of from about 0.5 to about 1.5 mole % of the composition.Type: GrantFiled: December 30, 2003Date of Patent: February 22, 2005Assignee: General Electric CompanyInventors: Mark Daniel Gorman, Irene Spitsberg, Brett Allen Boutwell, Ramgopal Darolia, Robert William Bruce, Venkat Subramanian Venkataramani, Anthony Mark Thompson, Antonio Mogro-Campera
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Patent number: 6849343Abstract: Interference pigment flakes and foils are provided which have color shifting properties. The pigment flakes can have a symmetrical coating structure on opposing sides of a reflector layer, can have an asymmetrical coating structure with all of the layers on one side of the reflector layer, or can be formed with encapsulating coatings around a core reflector layer. The coating structure of the flakes and foils includes a reflector layer, a dielectric layer on the reflector layer, and a titanium-containing absorber layer on the dielectric layer. The pigment flakes and foils exhibit a discrete color shift so as to have a first color at a first angle of incident light or viewing and a second color different from the first color at a second angle of incident light or viewing. The pigment flakes can be interspersed into liquid media such as paints or inks to produce colorant compositions for subsequent application to objects or papers.Type: GrantFiled: April 14, 2003Date of Patent: February 1, 2005Assignee: Flex Products, Inc.Inventors: Roger W. Phillips, Charlotte R. LeGallee, Paul T. Kohlmann, Vladimir Raksha, Alberto Argoitia
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Patent number: 6835465Abstract: 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: GrantFiled: May 13, 2002Date of Patent: December 28, 2004Assignee: Siemens Westinghouse Power CorporationInventors: David B. Allen, Ramesh Subramanian, Wolfram Beele
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Publication number: 20040258946Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.Type: ApplicationFiled: June 10, 2003Publication date: December 23, 2004Inventors: William P. Allen, William A. Veronesi, Robert J. Hall, Michael J. Maloney, John W. Appleby, Douglas C. Hague, Abdus S. Khan
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Patent number: 6833203Abstract: The present invention relates to an overlay coating which has improved strength properties. The overlay coating comprises a deposited layer of MCrAlY material containing discrete nitride particles therein. The nitride particles are present in a volume fraction in the range of 0.1% to 15.0% and have a particle size in the range of from 0.1 microns to 10.0 microns. The coating may also have oxide particles dispersed therein.Type: GrantFiled: August 5, 2002Date of Patent: December 21, 2004Assignee: United Technologies CorporationInventors: Sudhangshu Bose, Daniel A. Bales, Mark T. Ucasz, Merritt W. Wight, Steven M. Burns, Tyrus E. Royal
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Patent number: 6821641Abstract: An article protected by a thermal barrier coating system includes a substrate having a substrate surface, and a thermal barrier coating system overlying the substrate. The thermal barrier coating system has a thermal barrier coating formed of a thermal barrier coating material arranged as a plurality of columnar grains extending generally perpendicular to the substrate surface and having grain surfaces. A sintering inhibitor is within the columnar grains, either uniformly distributed or concentrated at the grain surfaces. The sintering inhibitor is lanthanum oxide, lanthanum chromate, chromium oxide, and/or yttrium chromate, mixtures thereof, mixtures thereof with aluminum oxide, modifications thereof wherein cobalt or manganese is substituted for chromium, precursors thereof, and reaction products thereof.Type: GrantFiled: October 22, 2001Date of Patent: November 23, 2004Assignee: General Electric CompanyInventors: Robert William Bruce, Nicholas Hamilton Burlingame
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Publication number: 20040229074Abstract: A coated article is provided that may be heat treated in certain example embodiments. A coating of the coated article includes zinc oxide inclusive layer(s) located under infrared (IR) reflecting layer(s) of a material such as silver. In certain example embodiments, coated articles are designed so as to realize higher visible transmission and/or lower sheet resistance values.Type: ApplicationFiled: March 15, 2004Publication date: November 18, 2004Inventors: Philip J. Lingle, Anton Dietrich, Jens-Peter Muller
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Publication number: 20040219290Abstract: 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: ApplicationFiled: April 30, 2003Publication date: November 4, 2004Inventors: Bangalore Aswatha Nagaraj, Eva Zielonka Lanman, Deborah Anne Schorr, Thomas John Tomlinson, Raymond William Heidorn, David Allen Kastrup, Craig Douglas Young