公开(公告)号：US20240175119A1

公开(公告)日：2024-05-30

申请号：US18071391

申请日：2022-11-29

Applicant: Applied Materials, Inc.

Inventor： Sukti CHATTERJEE ,  Yuriy MELNIK ,  Lance A. SCUDDER

IPC: C23C16/02 ,  C23C16/40 ,  C23C16/455

CPC classification number: C23C16/0272 ,  C23C16/40 ,  C23C16/405 ,  C23C16/45527

Abstract: Embodiments of the present disclosure relate generally to aerospace components containing protective coatings and methods for depositing the protective coatings. The protective coatings can be anti-coking coatings to reduce or suppress coke formation when the aerospace component is heated in the presence of a fuel in a reducing environment. In one or more embodiments, a method for depositing a protective coating on an aerospace component includes depositing a barrier layer on a surface of the aerospace component and depositing a carbon oxidation catalyst layer on the barrier layer. The barrier layer can be or include one or more metal oxides, such as chromium oxide, tungsten oxide, titanium oxide, vanadium oxide, alloys thereof, or any combination thereof. The carbon oxidation catalyst layer can be or include cerium oxide or doped cerium oxide or one or more oxygen storage materials.

公开(公告)号：US20190284692A1

公开(公告)日：2019-09-19

申请号：US16356681

申请日：2019-03-18

Applicant: Applied Materials, Inc.

Inventor： Yuriy MELNIK ,  Sukti CHATTERJEE ,  Kaushal GANGAKHEDKAR ,  Jonathan FRANKEL ,  Lance A. SCUDDER ,  Pravin K. NARWANKAR ,  David Alexander BRITZ ,  David Masayuki ISHIKAWA

IPC: C23C16/455

Abstract: A gas distribution assembly for applying a coating on an interior of a plurality of components includes a support with a plurality of component cavities formed within the support. Each component cavity corresponds to a respective component to fluidly couple with an interior of the respective component. A first gas source flow line is fluidly coupled with each of the component cavities to provide a first gas from a first gas source to each of the component cavities, and a second gas source flow line is fluidly coupled with each of the component cavities to provide a second gas from a second gas source to each of the component cavities.

公开(公告)号：US20210156267A1

公开(公告)日：2021-05-27

申请号：US16821427

申请日：2020-03-17

Applicant: Applied Materials, Inc.

Inventor： Sukti CHATTERJEE ,  Lance A. SCUDDER ,  David Alexander BRITZ ,  Kenichi OHNO

IPC: F01D5/28 ,  F01D5/00

Abstract: Embodiments of the present disclosure generally relate to protective coatings on turbine blades, turbine disks, and other aerospace components and methods for depositing the protective coatings. In one or more embodiments, a turbine blade includes a blade portion and a root coupled to the blade portion, where the root contains a protective coating disposed thereon. The protective coating is or contains one or more deposited crystalline film containing at least one of a metal oxide, a metal nitride, or a metal oxynitride and has a thickness of about 100 nm to about 10 μm. In some examples, a turbine blade assembly includes a disk and a plurality of the turbine blades coupled to the disk. The protective coating is disposed on the root on the turbine blade and/or a receiving surface on the turbine disk.

公开(公告)号：US20200340107A1

公开(公告)日：2020-10-29

申请号：US16850856

申请日：2020-04-16

Applicant: Applied Materials, Inc.

Inventor： Sukti CHATTERJEE ,  Lance A. SCUDDER ,  Yuriy MELNIK ,  David A. BRITZ ,  Thomas KNISLEY ,  Kenichi OHNO ,  Pravin K. NARWANKAR

IPC: C23C16/40 ,  C23C16/455 ,  C23C16/56 ,  C23C28/02

Abstract: Embodiments of the present disclosure generally relate to protective coatings on an aerospace component and methods for depositing the protective coatings. In one or more embodiments, a method for depositing a coating on an aerospace component includes depositing one or more layers on a surface of the aerospace component using an atomic layer deposition or chemical vapor deposition process, and performing a partial oxidation and annealing process to convert the one or more layers to a coalesced layer having a preferred phase crystalline assembly. During oxidation cycles, an aluminum depleted region is formed at the surface of the aerospace component, and an aluminum oxide region is formed between the aluminum depleted region and the coalesced layer. The coalesced layer forms a protective coating, which decreases the rate of aluminum depletion from the aerospace component and the rate of new aluminum oxide scale formation.

公开(公告)号：US20190284686A1

公开(公告)日：2019-09-19

申请号：US16356688

申请日：2019-03-18

Applicant: Applied Materials, Inc.

Inventor： Yuriy MELNIK ,  Sukti CHATTERJEE ,  Kaushal GANGAKHEDKAR ,  Jonathan FRANKEL ,  Lance A. SCUDDER ,  Pravin K. NARWANKAR ,  David Alexander BRITZ ,  Thomas KNISLEY ,  Mark SALY ,  David THOMPSON

IPC: C23C16/30 ,  C23C16/455 ,  C23C16/56 ,  F01D5/28 ,  F01D9/02 ,  F01D25/12 ,  F01D25/14 ,  F01D25/28 ,  F23R3/28

Abstract: Embodiments of the present disclosure generally relate to protective coatings on an aerospace component and methods for depositing the protective coatings. In one or more embodiments, a method for depositing a coating on an aerospace component includes exposing an aerospace component to a first precursor and a first reactant to form a first deposited layer on a surface of the aerospace component by a chemical vapor deposition (CVD) process or a first atomic layer deposition (ALD) process and exposing the aerospace component to a second precursor and a second reactant to form a second deposited layer on the first deposited layer by a second ALD process, where the first deposited layer and the second deposited layer have different compositions from each other.

公开(公告)号：US20230313380A1

公开(公告)日：2023-10-05

申请号：US18200497

申请日：2023-05-22

Applicant: Applied Materials, Inc.

Inventor： Sukti CHATTERJEE ,  Kenichi OHNO ,  Lance A. SCUDDER ,  Yuriy MELNIK ,  David A. BRITZ ,  Pravin K. NARWANKAR ,  Thomas KNISLEY ,  Mark SALY ,  Jeffrey ANTHIS

IPC: C23C16/56 ,  C22C19/03 ,  C23C16/40

CPC classification number: C23C16/56 ,  C22C19/03 ,  C23C16/405

Abstract: Embodiments of the present disclosure generally relate to protective coatings on aerospace components and methods for depositing the protective coatings. In one or more embodiments, an aerospace component has a body containing a nickel superalloy, a metal oxide template layer disposed on the body, and an aluminum oxide layer disposed between the body of the aerospace component and the metal oxide template layer. The metal oxide template layer contains chromium oxide, chromium oxide hydroxide, or a combination thereof. The aluminum oxide layer contains α-Al2O3. The metal oxide template layer and the aluminum oxide layer have a corundum crystal structure and have crystal structures with a lattice mismatch of about 0.1% to about 10%.

公开(公告)号：US20230167546A1

公开(公告)日：2023-06-01

申请号：US18159529

申请日：2023-01-25

Applicant: Applied Materials, Inc.

Inventor： Sukti CHATTERJEE ,  Lance A. SCUDDER ,  Yuriy MELNIK ,  David Alexander BRITZ ,  Thomas KNISLEY ,  Kenichi OHNO ,  Pravin K. NARWANKAR

IPC: C23C16/40 ,  C23C16/455 ,  C23C28/02 ,  C23C16/56

CPC classification number: C23C16/403 ,  C23C16/56 ,  C23C16/405 ,  C23C16/45525 ,  C23C28/02 ,  B64F5/40

Abstract: Embodiments of the present disclosure generally relate to protective coatings on an aerospace component and methods for depositing the protective coatings. In one or more embodiments, a method for depositing a coating on an aerospace component includes depositing one or more layers on a surface of the aerospace component using an atomic layer deposition or chemical vapor deposition process, and performing a partial oxidation and annealing process to convert the one or more layers to a coalesced layer having a preferred phase crystalline assembly. During oxidation cycles, an aluminum depleted region is formed at the surface of the aerospace component, and an aluminum oxide region is formed between the aluminum depleted region and the coalesced layer. The coalesced layer forms a protective coating, which decreases the rate of aluminum depletion from the aerospace component and the rate of new aluminum oxide scale formation.

公开(公告)号：US20220154335A1

公开(公告)日：2022-05-19

申请号：US16951837

申请日：2020-11-18

Applicant: Applied Materials, Inc.

Inventor： Sukti CHATTERJEE ,  David Alexander BRITZ ,  Lance A. SCUDDER

IPC: C23C16/455 ,  C23C16/40 ,  B64C1/40

Abstract: Embodiments of the present disclosure generally relate to protective coatings on aerospace components and methods for depositing the protective coatings. In one or more embodiments, an aerospace component containing a protective coating is provided and contains a superalloy substrate and a bond coating disposed on the superalloy substrate. The protective coating also contains a thermal barrier coating containing yttria-stabilized zirconia disposed on the bond coating, an oxide coating disposed on the thermal barrier coating, and an optional capping layer disposed on the oxide coating. The oxide coating contains a film stack containing two or more pairs of a first film and a second film, where the first film contains a first metal oxide and the second film contains a second metal oxide, and the first metal oxide has a different composition than the second metal oxide. The capping layer contains aluminum oxide, calcium oxide, magnesium oxide, or any combination thereof.

公开(公告)号：US20220002883A1

公开(公告)日：2022-01-06

申请号：US17339411

申请日：2021-06-04

Applicant: Applied Materials, Inc.

Inventor： Abhishek MANDAL ,  Nitin DEEPAK ,  Neha GUPTA ,  Prerna Sonthalia GORADIA ,  Ankur KADAM ,  Kenichi OHNO ,  David Alexander BRITZ ,  Lance A. SCUDDER

IPC: C23G1/10 ,  C23C16/02 ,  C23C16/34 ,  C23C16/40 ,  C11D11/00 ,  C11D7/32 ,  C11D7/06 ,  C11D7/08 ,  B64F5/40

Abstract: Embodiments of the present disclosure generally relate to methods for refurbishing aerospace components by removing corrosion and depositing protective coatings. In one or more embodiments, a method of refurbishing an aerospace component includes exposing the aerospace component containing corrosion to an aqueous cleaning solution. The aerospace component contains a nickel superalloy, an aluminide layer disposed on the nickel superalloy, and an aluminum oxide layer disposed on the aluminide layer. The method includes removing the corrosion from a portion of the aluminum oxide layer with the aqueous cleaning solution to reveal the aluminum oxide layer, then exposing the aluminum oxide layer to a post-rinse, and forming a protective coating on the aluminum oxide layer.

公开(公告)号：US20230050169A1

公开(公告)日：2023-02-16

申请号：US17977651

申请日：2022-10-31

Applicant: Applied Materials, Inc.

Inventor： David Alexander BRITZ ,  Lance A. SCUDDER ,  Yuriy MELNIK ,  Sukti CHATTERJEE

IPC: C23C16/34 ,  C23C16/455 ,  C23C28/04 ,  C23C16/40 ,  C23C16/50

Abstract: Embodiments of the present disclosure generally relate to protective coatings on various substrates including aerospace components and methods for depositing the protective coatings. In one or more embodiments, an aerospace component has a protective coating containing an aluminum oxide layer disposed on a surface of the aerospace component, a metal-containing catalytic layer disposed on the aluminum oxide layer, and a boron nitride layer disposed on the metal-containing catalytic layer. The aerospace component contains a superalloy having at least nickel and aluminum. In some examples, the aerospace component is a turbine blade, a turbine vane, a support member, a frame, a rib, a fin, a pin fin, a fuel nozzle, a combustor liner, a combustor shield, a heat exchanger, a fuel line, a fuel valve, an internal cooling channel, or any combination thereof.