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    Bi-layer HVOF coating with controlled porosity for use in thermal barrier coatings
    3.
    发明申请
    Bi-layer HVOF coating with controlled porosity for use in thermal barrier coatings 失效
    双层HVOF涂层，具有受控孔隙度，用于热障涂层

    公开(公告)号：US20050260434A1

    公开(公告)日：2005-11-24

    申请号：US10847357

    申请日：2004-05-18

    申请人： Warren Nelson ,  Jon Schaeffer ,  Sharon Swede ,  David Bucci ,  Joseph Debarro ,  Terry Strout ,  Tyrone Mortensen

    发明人： Warren Nelson ,  Jon Schaeffer ,  Sharon Swede ,  David Bucci ,  Joseph Debarro ,  Terry Strout ,  Tyrone Mortensen

    IPC分类号： F01D5/28 ,  C23C4/04 ,  C23C4/08 ,  C23C4/12 ,  C23C28/00 ,  F02C7/00 ,  B32B15/04

    CPC分类号： C23C28/325 ,  C23C4/18 ,  C23C26/00 ,  C23C28/3215 ,  C23C28/3455 ,  Y02T50/67 ,  Y10T428/12479 ,  Y10T428/12569 ,  Y10T428/12611 ,  Y10T428/12736 ,  Y10T428/12847 ,  Y10T428/26 ,  Y10T428/263 ,  Y10T428/31681

    摘要： A bi-layer bond coating for use on metal alloy components exposed to hostile thermal and chemical environment, such as a gas turbine engine used to generate electricity and the method for applying such coatings. The preferred coatings include a bi-layer bond coat applied to the metal substrate, with both layers being applied using high velocity oxy-fuel (HVOF) thermal spraying. In one embodiment, bond coatings in accordance with the invention can be used in combination with a thermal barrier coating (“TBC”). However, the invention can also take other forms, such as a stand alone overlay coating. Bi-layer bond coatings in accordance with the invention consist of a dense first inner layer (such as iron, nickel or cobalt-based alloys) that provides oxidation protection to the metal substrate, and a second outer layer having controlled porosity that tends to promote roughness, mechanical compliance, and promotes adherence of the TBC. Preferably, the outer, less dense layer of the bi-layer bond coat is formed from a mixture of metallic powder and polyester to adjust and control the porosity, but without sacrificing mechanical compliance. Together, the layers enhance adherence to the substrate and improve the overall life of the coating system.

    摘要翻译： 用于暴露于恶劣的热和化学环境的金属合金部件的双层粘合涂层，例如用于发电的燃气涡轮发动机和施加这种涂层的方法。 优选的涂层包括施加到金属基底上的双层粘合涂层，其中使用高速氧 - 燃料（HVOF）热喷涂施加两层。 在一个实施方案中，根据本发明的粘合剂涂层可以与热障涂层（“TBC”）组合使用。 然而，本发明也可以采取其它形式，例如独立覆盖涂层。 根据本发明的双层粘合涂层由致密的第一内层（例如铁，镍或钴基合金）组成，其向金属基底提供氧化保护，以及具有趋向促进的受控孔隙率的第二外层 粗糙度，机械依从性，并促进TBC的坚持。 优选地，双层粘合涂层的外部，较不致密的层由金属粉末和聚酯的混合物形成，以调节和控制孔隙率，但不牺牲机械顺应性。 这些层一起增强了对基材的粘附性并提高了涂层体系的总体寿命。

    METHOD FOR FORMING A PROTECTIVE COATING WITH ENHANCED ADHESION BETWEEN LAYERS
    5.
    发明申请
    METHOD FOR FORMING A PROTECTIVE COATING WITH ENHANCED ADHESION BETWEEN LAYERS 有权
    在层之间形成具有增强粘合力的保护涂层的方法

    公开(公告)号：US20070178247A1

    公开(公告)日：2007-08-02

    申请号：US11307266

    申请日：2006-01-30

    申请人： David Bucci ,  Daniel Nowak ,  Paul Dimascio

    发明人： David Bucci ,  Daniel Nowak ,  Paul Dimascio

    IPC分类号： B05D3/00 ,  B05D7/00 ,  B05D1/08

    CPC分类号： C23C10/60 ,  C23C10/06 ,  C23C10/48 ,  C23C26/00 ,  Y10T428/12472

    摘要： A method for forming a protective coating on a substrate comprising, applying a bond coating to the substrate, the bond coating having a first surface roughness, ionizing an inert gas which flows into the surface of the bond coating so as to impart a second surface roughness to the bond coating greater than the first surface roughness, wherein the inert gas is ionized and caused to flow into the surface of the bond coating by a reverse polarity current supplied to an electrode which removes at least one electron from the inert gas, and applying a top coating to the bond coating. Additionally, a method for preparing a surface to receive and adhere to a coating comprising roughening the surface to create a micro-roughening network on the surface. In addition, a method of improving strain tolerance and cyclic spallation life of a protective coating.

    摘要翻译： 一种在基材上形成保护涂层的方法，包括：向所述基材施加粘合涂层，所述粘合涂层具有第一表面粗糙度，电离惰性气体，所述惰性气体流入所述粘结涂层的表面，以赋予第二表面粗糙度 到大于第一表面粗糙度的粘结涂层，其中惰性气体被电离并通过提供给从惰性气体中除去至少一个电子的电极的反极性电流流入粘合涂层的表面，并施加 粘合涂层的顶部涂层。 另外，一种制备表面以接收和粘附到涂层上的方法，包括使表面变粗糙以在表面上产生微粗糙化网络。 另外，提高保护涂层的耐应变性和循环剥落寿命的方法。

    Method for forming a protective coating with enhanced adhesion between layers
    8.
    发明授权
    Method for forming a protective coating with enhanced adhesion between layers 有权
    用于形成具有增强的层之间的粘合力的保护涂层的方法

    公开(公告)号：US08697195B2

    公开(公告)日：2014-04-15

    申请号：US11307266

    申请日：2006-01-30

    申请人： David Bucci ,  Daniel A. Nowak ,  Paul S. Dimascio

    发明人： David Bucci ,  Daniel A. Nowak ,  Paul S. Dimascio

    IPC分类号： B05D3/04 ,  C23C14/02 ,  H05H1/00 ,  H05H1/32

    CPC分类号： C23C10/60 ,  C23C10/06 ,  C23C10/48 ,  C23C26/00 ,  Y10T428/12472

    摘要： A method for forming a protective coating on a substrate comprising, applying a bond coating to the substrate, the bond coating having a first surface roughness, ionizing an inert gas which flows into the surface of the bond coating so as to impart a second surface roughness to the bond coating greater than the first surface roughness, wherein the inert gas is ionized and caused to flow into the surface of the bond coating by a reverse polarity current supplied to an electrode which removes at least one electron from the inert gas, and applying a top coating to the bond coating. Additionally, a method for preparing a surface to receive and adhere to a coating comprising roughening the surface to create a micro-roughening network on the surface. In addition, a method of improving strain tolerance and cyclic spallation life of a protective coating.

    摘要翻译： 一种在基材上形成保护涂层的方法，包括：向所述基材施加粘合涂层，所述粘合涂层具有第一表面粗糙度，电离惰性气体，所述惰性气体流入所述粘结涂层的表面，以赋予第二表面粗糙度 到大于第一表面粗糙度的粘结涂层，其中惰性气体被电离并通过提供给从惰性气体中除去至少一个电子的电极的反极性电流流入粘合涂层的表面，并施加 粘合涂层的顶部涂层。 另外，一种制备表面以接收和粘附到涂层上的方法，包括使表面变粗糙以在表面上产生微粗糙化网络。 另外，提高保护涂层的耐应变性和循环剥落寿命的方法。

    Method for coating metals
    10.
    发明申请
    Method for coating metals 有权
    金属涂层方法

    公开(公告)号：US20070110900A1

    公开(公告)日：2007-05-17

    申请号：US11283248

    申请日：2005-11-17

    申请人： Daniel Nowak ,  Paul DiMascio ,  David Bucci

    发明人： Daniel Nowak ,  Paul DiMascio ,  David Bucci

    IPC分类号： B05D3/10 ,  B05D1/08 ,  C23C4/00

    CPC分类号： C23C4/02 ,  C23C4/11 ,  C23C28/3215 ,  C23C28/345 ,  C23C28/3455

    摘要： Disclosed herein are methods for coating metal substrates, systems therefore, and articles made therefrom. In one embodiment, the method of coating a metal substrate comprises: disposing a metallic bond coating on the metal substrate, creating ions with a reverse polarity high frequency apparatus at a frequency of greater than or equal to about 2.5 kHz, roughening the surface with the ions to a subsequent average surface roughness of greater than or equal to about 5 μm, and disposing a ceramic coating on the metallic bond coating surface. The metallic bond coating had a surface with an initial average surface roughness of less than or equal to about 1 μm.

    摘要翻译： 本文公开了用于涂覆金属基底，系统以及由其制成的制品的方法。 在一个实施例中，涂覆金属衬底的方法包括：在金属衬底上设置金属粘合涂层，以大于或等于约2.5kHz的频率用反极性高频装置产生离子，使表面粗糙化 离子到随后的平均表面粗糙度大于或等于约5μm，并且在金属粘合涂层表面上设置陶瓷涂层。 金属粘合涂层具有初始平均表面粗糙度小于或等于约1um的表面。