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1.发明授权公开(公告)号：US11827574B2
公开(公告)日：2023-11-28
申请号：US17444677
申请日：2021-08-09
CPC分类号： C04B41/0072 , B05D3/104 , B32B18/00 , C04B41/87 , F05D2230/22 , F05D2300/2283 , F05D2300/6033
摘要： A method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate to form an article is provided. The method includes the steps of etching the surface of the ceramic substrate to texture the surface, disposing an environmental barrier coating on the etched surface of the ceramic substrate. The environmental barrier coating includes a rare earth silicate, and pressure sintering the environmental barrier coating on the etched surface of the ceramic substrate in an inert or nitrogen atmosphere such that at least a portion of the environmental barrier coating is disposed in the texture of the surface of the ceramic substrate thereby forming the article.
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公开(公告)号：US11236023B2
公开(公告)日：2022-02-01
申请号：US16183276
申请日：2018-11-07
发明人： Terence Whalen , Bahram Jadidian , Reza Oboodi
IPC分类号： C04B41/50 , C03C8/02 , C03C8/16 , C04B41/45 , C04B41/52 , C04B41/53 , C04B41/86 , C04B41/89 , C04B41/91
摘要： A method for forming a protective coating on a surface of a ceramic substrate includes combining a rare-earth oxide, alumina, and silica to form a powder, etching the surface of the ceramic substrate, applying the powder on the etched surface in an amount of from about 0.001 to about 0.1 g/cm2 to reduce capture of bubbles from off-gassing of the ceramic substrate, heating the powder for a time of from about 5 to about 60 minutes to a temperature at or above the melting point such that the powder melts and forms a molten coating on the surface that has a minimized number of bubbles, and cooling the molten coating to ambient temperature to form the protective coating disposed on and in direct contact with the surface of the ceramic substrate such that the protective coating has a thickness of less than about 1 mil.
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公开(公告)号：US20210180190A1
公开(公告)日：2021-06-17
申请号：US16701974
申请日：2019-12-03
发明人： Reza Oboodi , James Piascik , Donald M. Olson , Natalie Kruk , Terence Whalen
IPC分类号： C23C18/12 , C23C18/04 , F01D5/22 , F01D25/00 , C04B41/50 , F23R3/00 , C04B41/00 , F01D5/00 , F01D5/28 , C04B41/85
摘要： A coated turbomachine component includes a ceramic component body having a principal surface. The component includes a high temperature coating. The high temperature coating includes a sintered coating body bonded directly to and intimately contacting the principal surface of the ceramic component body. The sintered coating body has a minimum porosity adjacent the principal surface and a maximum porosity at a location further from the principal surface, as taken along an axis orthogonal to the principal surface.
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公开(公告)号：US20190020229A1
公开(公告)日：2019-01-17
申请号：US16121146
申请日：2018-09-04
发明人： James Piascik , Reza Oboodi , Paul Chipko , Martin Carlin Baker , Jimmy Wiggins , Leroy Allen Fizer
摘要： Embodiments of laminated stator cores suitable for usage in high temperature applications are provided, as are embodiments of methods for manufacturing high temperature laminated stator core. In one embodiment, the method includes obtaining a plurality of coated laminates each comprising a laminate over which a coating precursor layer is formed. The coating precursor layer contain inorganic dielectric particles having a softening point. The plurality of coated laminates are arranged in a laminate stack, which is then fired at temperatures equal to or greater than the softening point of the inorganic dielectric particles. During firing, a compressive force is applied to the laminate stack sufficient to consolidate the inorganic dielectric particles into a plurality of coherent interlaminate dielectric layers electrically insulating and bonding together the plurality of coated laminates as the high temperature laminated stator core.
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公开(公告)号：US11131026B2
公开(公告)日：2021-09-28
申请号：US16989247
申请日：2020-08-10
发明人： Reza Oboodi , James Piascik , Donald M. Olson , Natalie Kruk , Terence Whalen
IPC分类号： C23C18/12 , C23C18/04 , F01D5/22 , F01D25/00 , C04B41/50 , F23R3/00 , C04B41/00 , F01D5/00 , F01D5/28 , C04B41/85
摘要： Methods for forming sintered-bonded high temperature coatings over ceramic turbomachine components are provided, as are ceramic turbomachine components having such high temperature coatings formed thereover. In one embodiment, the method includes the step or process of removing a surface oxide layer from the ceramic component body of a turbomachine component to expose a treated surface of the ceramic component body. A first layer of coating precursor material, which has a solids content composed predominately of at least one rare earth silicate by weight percentage, is applied to the treated surface. The first layer of the coating precursor material is then heat treated to sinter the solids content and form a first sintered coating layer bonded to the treated surface. The steps of applying and sintering the coating precursor may be repeated, as desired, to build a sintered coating body to a desired thickness over the ceramic component body.
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公开(公告)号：US10801111B2
公开(公告)日：2020-10-13
申请号：US15608574
申请日：2017-05-30
发明人： Reza Oboodi , James Piascik , Donald M. Olson , Natalie Kruk , Terence Whalen
IPC分类号： C23C18/12 , C23C18/04 , F01D5/22 , F01D25/00 , C04B41/50 , F23R3/00 , C04B41/00 , F01D5/00 , F01D5/28 , C04B41/85
摘要： Methods for forming sintered-bonded high temperature coatings over ceramic turbomachine components are provided, as are ceramic turbomachine components having such high temperature coatings formed thereover. In one embodiment, the method includes the step or process of removing a surface oxide layer from the ceramic component body of a turbomachine component to expose a treated surface of the ceramic component body. A first layer of coating precursor material, which has a solids content composed predominately of at least one rare earth silicate by weight percentage, is applied to the treated surface. The first layer of the coating precursor material is then heat treated to sinter the solids content and form a first sintered coating layer bonded to the treated surface. The steps of applying and sintering the coating precursor may be repeated, as desired, to build a sintered coating body to a desired thickness over the ceramic component body.
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公开(公告)号：US20200207672A1
公开(公告)日：2020-07-02
申请号：US16811726
申请日：2020-03-06
发明人： Reza Oboodi , Eric Passman , Bahram Jadidian
摘要： A protective coating system includes a substrate that has an exterior surface exhibiting a degree of valley/hill surface irregularity including a plurality of hills and a plurality of valleys and a first coating layer formed directly on to the exterior surface of the substrate and that conforms to the exterior surface of the substrate such that the first coating layer has a non-uniform coating thickness over the substrate. The protective coating system further includes a second coating layer formed directly on to the exterior surface of the first coating layer. The second coating layer includes a plurality of pores within the second coating layer. Still further, the protective coating system includes a third coating layer formed within at least some of the plurality of pores within the second coating layer.
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8.发明申请公开(公告)号：US20180346388A1
公开(公告)日：2018-12-06
申请号：US16056060
申请日：2018-08-06
发明人： Reza Oboodi , Eric Passman , Bahram Jadidian
IPC分类号： C04B41/52 , C04B41/89 , F01D5/28 , C04B41/00 , C04B35/565 , C04B35/80 , C04B41/45 , C04B41/50
CPC分类号： C04B41/52 , C04B41/009 , C04B41/89 , F01D5/282 , F01D5/284 , F01D5/288 , F05D2300/2261 , F05D2300/6033 , Y02T50/672 , Y10T428/24364 , Y10T428/24612 , Y10T428/249955 , Y10T428/24999 , Y10T428/26 , C04B35/565 , C04B35/806 , C04B41/4537 , C04B41/5024 , C04B41/4582 , C04B41/5032 , C04B41/522 , C04B41/5048 , C04B41/5042 , C04B41/50
摘要： Methods for fabricating protective coating systems for gas turbine engine applications are provided. An exemplary method of applying a protective coating to a substrate includes the steps of providing a substrate formed of a ceramic matrix composite material, forming a first coating layer directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and forming a second coating layer directly on to the first coating layer and comprising a thermal barrier material. The method optionally includes forming a third coating layer partially directly on to the second coating layer and partially within at least some of the plurality of pores of the second coating layer.
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公开(公告)号：US11370717B2
公开(公告)日：2022-06-28
申请号：US16811726
申请日：2020-03-06
发明人： Reza Oboodi , Eric Passman , Bahram Jadidian
摘要： A protective coating system includes a substrate that has an exterior surface exhibiting a degree of valley/hill surface irregularity including a plurality of hills and a plurality of valleys and a first coating layer formed directly on to the exterior surface of the substrate and that conforms to the exterior surface of the substrate such that the first coating layer has a non-uniform coating thickness over the substrate. The protective coating system further includes a second coating layer formed directly on to the exterior surface of the first coating layer. The second coating layer includes a plurality of pores within the second coating layer. Still further, the protective coating system includes a third coating layer formed within at least some of the plurality of pores within the second coating layer.
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10.发明授权公开(公告)号：US11084761B2
公开(公告)日：2021-08-10
申请号：US16131279
申请日：2018-09-14
摘要： A method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate to form an article includes the steps of etching the surface of the ceramic substrate to texture the surface, disposing an environmental barrier coating on the etched surface of the ceramic substrate wherein the environmental barrier coating includes a rare earth silicate, and pressure sintering the environmental barrier coating on the etched surface of the ceramic substrate in an inert or nitrogen atmosphere at a pressure of greater than atmospheric pressure such that at least a portion of the environmental barrier coating is disposed in the texture of the surface of the ceramic substrate thereby forming the article.
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