Building the Future: A Visual Journey by mpt-llc

Aluminizing of Metal Substrates filed in 1911 by Tyco Van Aller

 Abstract: One of the objects of my invention is to treat iron, copper and similar metals so as to produce such a condition upon the surface of the metal or within it that it may be heated to a high temperature for practically an indefinite period without any deleterious effect upon the metal. In carrying out my invention in one aspect I employ the metal aluminum for producing the desired condition. I have found that iron, copper and similar metals when heated with aluminum powder to a suitable temperature and under suitable conditions arrive at such a condition. 

Gas Phase Aluminizing Method  filed in 1925 by Martin 

Abstract: My invention relates, in general, to a process for coating one metal with another which involves the deposition of the latter metal by dry chemical reaction, and also to apparatus for carrying out this process and to the products resulting from such process. The principal object of my invention resides in the provision of an improved process for coating or depositing one metal on another whereby a metallic object covered by employing such process will be provided with an outer ,surface layer consisting of an alloy of the deposited metal and the metal of the coated object having one or more of certain desirable properties, .such as resistance to oxidation at ordinary temperatures or at high temperatures such as those encountered in furnaces, toughness, malleability, hardness and enhanced appearance, depending upon the metals employed and upon the purposes for which the coated objects are designed to be used. It is practicable by my improved process to cover an object formed of any of a number of different metals, notably either iron, steel, cast iron, copper or nickel, with an alloy of aluminum and the metal of which the object is formed.

 Superalloy Pack Cementation Coating Process (PWA 73) filed in 1968 by Boone & Goward 

 Abstract: An overhaul process for coated gas turbine engine components is described wherein the components are: removed from the engine at or prior to the onset of significant coating penetration as evidenced by the loss of one or more substrate components; recoated in a pack cementation process of high aluminum activity without stripping of the old coating; and are subsequently heat treated to promote the formation of aluminides having an aluminum content less than that corresponding to Ni2Al3.

 Platinum Modified Aluminide Coating filed in 1971 by Bungardt 

 Abstract: Nickel and/or cobalt-based alloys are given a protective coating by diffusing into the surface of the alloy metallic aluminum and one or more metals of the platinum groups.

 “Above the Pack” Coating Process (PWA 275)  filed in 1977 by Benden 

 Abstract: Disclosed is an improved apparatus for depositing a coating on the internal surfaces of hollow articles by gas phase deposition. The apparatus typically includes a sheet metal enclosure having a manifold member which defines a first and second chamber therein. The first chamber is adapted to contain a powder mixture for generating a coating gas whereas the second chamber is adapted to house the articles to be coated. The manifold member includes hollow tubes or other connector means extending there through to connect the interior of the articles in gas flow relation to the first chamber where the coating gas is generated. A source external of the enclosure supplies carrier gas to the first chamber at a controlled flow rate via tube means. The carrier gas transports the coating gas generated in the first chamber through the manifold tubes and then into the internal passages of the article to effect deposition. The positive flow of coating gas through the internal passages provides a substantially uniform coating thickness over the entire internal surface area of each article.

 Vapor Phase Aluminizing (SNECMA VPA)  filed in 1982 by Gauje 

Abstract: The present invention concerns a vapor phase process for the deposition of at least one protective metal coating on a metal piece. The coating is aluminum, chromium, titanium, or a derivative of these metals or alloys or mixtures. The coating is effected by the reaction of the surface of the metal piece, suitably heated in an enclosure, with a halide compound of the coating metal which is formed by the reaction, in the enclosure, between a chemical halide compound with a donor. The donor consists of the coating metal or an alloy formed in a thin sheet, the surface area being of the same order of magnitude as that of the piece to be coated, located so that the surface area faces the metal piece.

 Pulse Aluminizing  filed in 1982 by Restall 

Abstract: A metallic or ceramic layer is deposited on a component by plasma spraying. This produces a rough, still porous, coating which is poorly bonded at the interface with the substrate. Aluminium or chromium is vapor deposited under pulsating pressure to react with the substrate to form an oxidation resistant coating of Ni Al (intermetallic) or Ni Cr (solid solution) which may include ceramic particles and is aerodynamically smooth.

 Chemical Vapor Deposition of Aluminide Coatings (Howmet CVD)  filed 1991 by Punola 

Abstract: A chemical vapor deposition (CVD) method utilizing an apparatus comprising a reactor having a coating chamber at elevated temperature, means for supporting substrates to be coated at different zones in the coating chamber, and means for supplying a gaseous reactant stream to the chamber for distribution to the coating zones in a manner that the stream is heated to substantially different temperatures at different coating zones. Reactivity-altering material is disposed at the coating zones for contact by the reactant stream supplied thereto before the reactant stream contacts a substrate at the zones. The reactivity-altering material includes a composition that differs between coating zones in dependence on the reactant stream temperatures at the coating zones as necessary to alter the reactivity of the reactant (i.e., activity of a particular chemical specie of the reactant stream) stream at the coating zones in a manner to provide substantially the same reactant reactivity at all coating zones. CVD coatings are thereby produced on the substrates that exhibit improved uniformity in composition and thickness from one substrate to the next at the different zones.

 Active Element Modified Alumindes via CVD Codeposition  filed in 1994 by Warnes 

Abstract: CVD aluminide coatings including a small concentration of a reactive, gettering element for surface active impurities dispersed therein are formed for improved oxidation resistance. The aluminide coatings are formed by CVD codeposition of Al and the gettering element on the substrate using coating gases for the gettering element generated either outside or inside the coating retort depending on the chlorination temperature needed for the particular gettering element.

 Gamma-Gamma Prime Aluminide Coating filed in 2003 by Gleeson 

Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a gamma-Ni + gamma′-Ni3Al phase constitution, and a coating including the alloy.

 Yttria Stabilized Zirconia (YSZ) Thermal Barrier Coating filed in 1976 by Stecura 

Abstract: A coating system which contains a bond coating and a thermal barrier coating is applied to metal surfaces such as turbine blades and which provides both low thermal conductivity and improved adherence when exposed to high temperature gases or liquids. The bond coating contains NiCrAlY and the thermal barrier coating contains a reflective oxide. The reflective oxides ZrO.sub.2 --Y.sub.2 O.sub.3 and ZrO.sub.2 --MgO have demonstrated significant utility in high temperature turbine applications.

 Columnar Grained (EB-PVD) Thermal Barrier Coating  with MCrAlY Bond Coat  filed 1980 by Strangman 

Abstract: A coated article and method for producing the coated article are described. The article is coated with a system which provides protection against oxidation and corrosion and which significantly reduces the substrate temperature. An MCrAlY layer is applied to the article to be protected and a columnar grain ceramic is applied by vapor deposition to the MCrAlY coated article. An alumina layer which exists between the MCrAlY layer and the columnar ceramic layer provides for the adherence of the columnar layer to the MCrAlY layer.

 Thermal Barrier Coating System with Platinum Aluminide Bond Coat  filed in 1984 by Strangman (Patent issuance delayed until 1996 by govt secrecy order) 

Abstract: An improvement in a thermal barrier coating for superalloy turbine engine components subjected to high operating temperatures, such as turbine airfoils, e.g., vanes and blades, is disclosed which eliminates the expensive MCrAlY oxidation resistant bond coating underlayer for a columnar grained ceramic thermal barrier coating. In accordance with my present invention, a relatively low cost thermal barrier coating system for superalloy turbine components is provided which utilizes a diffusion aluminide coating layer as the oxidation resistant bonding surface for the columnar grained ceramic insulating coating.

 Thermal Barrier Coating for Substrates and Process for Producing It filed  in 1989 by Taylor 

Abstract: A thermal barrier coating for substrates comprising zirconia partially stabilized by yttria and having a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance. The invention also discloses a process for producing the thermal barrier coating.

 Thermal Barrier Coating System with Hyperstoichiometric Platinum Aluminide Bond Coat  filed in 1995 by Murphy 

Abstract: A thermal barrier protected nickel based or cobalt based superalloy component for use in a gas turbine engine includes a thermal barrier coating system having a multi-layered structure. The first bondcoat layer of the thermal barrier coating system comprises a chemical vapor deposited, platinum modified diffusion aluminide layer on the superalloy component (substrate). The diffusion aluminide layer includes an inner diffusion zone proximate the substrate and an outer layer region comprising a platinum modified (platinum-bearing) intermediate phase of aluminum and at least one of nickel and cobalt depending on the superalloy composition. The intermediate phase is a non-ordered solid solution having a range of compositions and is free of other phase constituents. The intermediate phase has an average aluminum concentration in the range of about 18 to about 26% by weight, an average platinum concentration in the range of about 8 to about 35% by weight, and an average nickel concentration in the range of about 50 to 60% by weight and is non-stoichiometric relative to intermetallic compounds of aluminum and nickel, aluminum and cobalt, and aluminum and platinum. An adherent alpha alumina layer is thermally grown on the diffusion aluminide layer and receives an outer ceramic thermal barrier layer deposited thereon.

 Thermal Barrier Coating System with a Platinum Modified Gamma-Gamma Prime Bond Coat filed in 1995 by Rickersby 

Abstract: A ceramic thermal barrier coating layer for a superalloy article is caused to adhere to the superalloy article by applying platinum to the superalloy article and heat treating at a temperature of 1100° C. to 1200° C. for one hour. This causes aluminum to diffuse from the superalloy article into the platinum to form a platinum enriched outer layer which generally includes a platinum enriched gamma phase and a platinum enriched gamma prime phase. An alumina layer is formed between the platinum enriched outer layer and a ceramic coating. The platinum enriched gamma phase and the platinum enriched gamma prime phase in the outer layer reduces the migration of transition metal elements to the ceramic coating to enable a very pure alumina layer to be formed.

 Vitallium Alloy Turbine Bucket For Exhaust Turbine Superchargers filed in  1941 by Merrick 

Abstract: With the improvement of aircraft and their engines, the necessity for better turbine buckets for exhaust turbine superchargers and better materials for such turbine buckets has become urgent.The improvement of the present invention consists in forming the bucket by a casting process and of an alloy providing new and advantageous results not equaled by the alloys previously used in making such bucket, and which alloy it would be hopeless to consider for a forged and machined bucket on account of the hardness and difficulty of machining and impracticability of forging the same.More specifically, the improvement of the present invention consists in providing a cast turbine bucket for exhaust turbine superchargers, such bucket being formed of a cobalt-chromium alloy, and, more particularly, formed of a cobalt, chromium, molybdenum alloy with the constituents combined and proportioned in a manner better to withstand the severe conditions to which such-buckets are subjected.