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    PHYSICAL VAPOR DEPOSITION PROCESS AND APPARATUS THEREFOR
    1.
    发明申请
    PHYSICAL VAPOR DEPOSITION PROCESS AND APPARATUS THEREFOR 审中-公开
    物理蒸气沉积工艺及其设备

    公开(公告)号：US20070160775A1

    公开(公告)日：2007-07-12

    申请号：US11306740

    申请日：2006-01-10

    申请人： Gillion Marijnissen ,  Eric Vergeldt ,  Joseph Rigney ,  Annejan Kloosterman ,  Ramgopal Darolia

    发明人： Gillion Marijnissen ,  Eric Vergeldt ,  Joseph Rigney ,  Annejan Kloosterman ,  Ramgopal Darolia

    IPC分类号： C23C8/00 ,  C23C16/00

    CPC分类号： C23C14/30 ,  C23C14/16 ,  C23C14/243 ,  C23C14/246

    摘要： A PVD process and apparatus for depositing a coating from multiple sources of materials with different vapor pressures. The process entails forming molten pools of different first and second materials in a coating chamber of the apparatus, supporting an article within the chamber, and evaporating the molten pools with an energy beam to deposit a coating on the article with a controlled composition that contains at least a first metal and a relatively lesser amount of at least one reactive metal having a lower vapor pressure than the first metal. The first material contains at least the first metal, and the second material contains the reactive metal and at least a second metal. The second and reactive metals are combined to cause the second material to have a lower melting temperature and wider melting range than the reactive metal.

    摘要翻译： 用于从具有不同蒸汽压力的多种材料源沉积涂层的PVD工艺和设备。 该方法需要在装置的涂覆室中形成不同的第一和第二材料的熔池，在室内支撑物品，并用能量束蒸发熔池，以将涂层沉积在具有受控组成的包含在 至少一种第一金属和相对较少量的至少一种具有比第一金属更低的蒸气压的活性金属。 第一材料至少包含第一金属，第二材料包含反应性金属和至少第二金属。 将第二和反应性金属组合以使第二材料具有比反应性金属更低的熔融温度和更宽的熔化范围。

    METHOD FOR REPAIRING COATED COMPONENTS USING NIAL BOND COATS
    7.
    发明申请
    METHOD FOR REPAIRING COATED COMPONENTS USING NIAL BOND COATS 有权
    使用NIAL BOND COATS修复涂层组件的方法

    公开(公告)号：US20060029723A1

    公开(公告)日：2006-02-09

    申请号：US10714430

    申请日：2003-11-13

    申请人： Joseph Rigney ,  Ching-Pang Lee ,  Ramgopal Darolia

    发明人： Joseph Rigney ,  Ching-Pang Lee ,  Ramgopal Darolia

    IPC分类号： C23C16/52 ,  B05D3/00

    CPC分类号： B23P6/002 ,  C23C10/02 ,  C23C10/60 ,  C23C28/321 ,  C23C28/3215 ,  C23C28/345 ,  C23C28/3455 ,  C23C28/36 ,  C25D3/50 ,  C25D7/00 ,  C25D7/008 ,  F05B2230/31 ,  F05B2230/90 ,  F05C2253/12

    摘要： According to an embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, and improve upon the prior bond coat is disclosed. The method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the base metal substrate removed. The portion of the base metal substrate removed has a thickness, Δt. The method also comprises applying a β phase NiAl overlay coating to the substrate, and determining the difference in thickness, Δx, between the β phase NiAl overlay coating and the previously removed bond coat. The method further comprises reapplying the top ceramic thermal barrier coating to a nominal thickness of t+Δt-Δx, wherein Δt compensates for the portion of removed base metal substrate. Advantageously, the coated airfoil contour dimensions of the high pressure turbine blade are restored to about the coated dimensions preceding the engine run.

    摘要翻译： 根据本发明的实施例，公开了一种已经暴露于发动机操作的用于修复涂覆的高压涡轮机叶片以恢复叶片的被覆翼型轮廓尺寸并改进先前的粘结涂层的方法。 该方法包括提供一种发动机运行的高压涡轮叶片，其包括由镍基合金制成的基底金属基底并且具有热障涂层系统。 热障涂层系统包括在基底金属基底上的扩散粘合涂层和包含氧化钇稳定的氧化锆材料的顶部陶瓷热障涂层。 顶部陶瓷热障涂层具有标称厚度t。 该方法还包括去除热障涂层系统，其中基底金属衬底的一部分也被去除，并且确定移除的母体金属衬底的厚度。 去除的贱金属基材的部分厚度为Deltat。 该方法还包括将β相NiAl覆盖涂层施加到基底上，并确定β相NiAl覆盖涂层与先前去除的粘结涂层之间的厚度差异Deltax。 该方法还包括将顶部陶瓷热障涂层重新施加到t + Deltat-Deltax的标称厚度，其中Deltat补偿去除的基底金属基底的部分。 有利地，高压涡轮机叶片的被覆翼型轮廓尺寸恢复到发动机运行之前的涂层尺寸。

    Method for repairing coated components
    9.
    发明申请
    Method for repairing coated components 有权
    修复涂层部件的方法

    公开(公告)号：US20050106316A1

    公开(公告)日：2005-05-19

    申请号：US10714213

    申请日：2003-11-13

    申请人： Joseph Rigney ,  Ching-Pang Lee ,  Ramgopal Darolia

    发明人： Joseph Rigney ,  Ching-Pang Lee ,  Ramgopal Darolia

    IPC分类号： B23P6/00 ,  C23C26/00 ,  C23C28/00 ,  F01D5/00 ,  F01D5/14 ,  F01D5/28 ,  F01D25/00 ,  F02C7/00 ,  B32B35/00

    CPC分类号： C23C28/321 ,  C23C26/00 ,  C23C28/325 ,  C23C28/3455 ,  F01D5/005 ,  F01D5/288 ,  F05D2230/80 ,  F05D2230/90 ,  F05D2300/501 ,  Y10T29/49318

    摘要： According to an embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, is disclosed. The method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the base metal substrate removed. The portion of the base metal substrate removed has a thickness, Δt. The method also comprises reapplying the diffusion bond coat to the substrate, wherein the bond coat is reapplied to a thickness, which is about the same as applied prior to the engine operation; and reapplying the top ceramic thermal barrier coating to a nominal thickness of t+Δt, wherein Δt compensates for the portion of removed base metal substrate. Advantageously, the coated airfoil contour dimensions of the high pressure turbine blade are restored to about the coated dimensions preceding the engine run.

    摘要翻译： 根据本发明的实施例，公开了一种已经暴露于发动机操作的用于修复涂覆的高压涡轮机叶片以恢复叶片的被覆翼型轮廓尺寸的方法。 该方法包括提供一种发动机运行的高压涡轮叶片，其包括由镍基合金制成的基底金属基底并且具有热障涂层系统。 热障涂层系统包括在基底金属基底上的扩散粘合涂层和包含氧化钇稳定的氧化锆材料的顶部陶瓷热障涂层。 顶部陶瓷热障涂层具有标称厚度t。 该方法还包括去除热障涂层系统，其中基底金属衬底的一部分也被去除，并且确定移除的母体金属衬底的厚度。 去除的贱金属基材的部分厚度为Deltat。 该方法还包括将扩散粘合涂层重新施加到基底上，其中粘结涂层重新施加到与发动机操作前相同的厚度; 并将顶部陶瓷热障涂层重新施加到标称厚度t + Deltat，其中Deltat补偿去除的基底金属基底的部分。 有利地，高压涡轮机叶片的被覆翼型轮廓尺寸恢复到发动机运行之前的涂层尺寸。

    BETA-PHASE NICKEL ALUMINIDE OVERLAY COATING AND PROCESS THEREFOR
    10.
    发明申请
    BETA-PHASE NICKEL ALUMINIDE OVERLAY COATING AND PROCESS THEREFOR 审中-公开
    BETA相镍合金镀层及其工艺

    公开(公告)号：US20050019491A1

    公开(公告)日：2005-01-27

    申请号：US10711584

    申请日：2004-09-27

    申请人： Irene Spitsberg ,  Joseph Rigney ,  Ramgopal Darolia ,  Elissa Lee ,  Jeffrey Pfaendtner

    发明人： Irene Spitsberg ,  Joseph Rigney ,  Ramgopal Darolia ,  Elissa Lee ,  Jeffrey Pfaendtner

    IPC分类号： C21D7/06 ,  C23C4/18 ,  C23C8/02 ,  C23C26/00 ,  C23C28/00 ,  B05D3/12

    CPC分类号： C23C28/321 ,  C21D7/06 ,  C23C4/18 ,  C23C8/02 ,  C23C26/00 ,  C23C28/345 ,  C23C28/3455 ,  Y10T428/12611 ,  Y10T428/12736 ,  Y10T428/12937 ,  Y10T428/12944

    摘要： A beta-phase nickel aluminide (NiAl) overlay coating (24) and method for modifying the grain structure of the coating (24) to improve its oxidation resistance. The coating (24) is deposited by a method that produces a grain structure characterized by grain boundaries (44) exposed at the outer coating surface (36). The grain boundaries (44) may also contain precipitates (40) as a result of the alloyed chemistry of the coating (24). During or after deposition, the overlay coating (24) is caused to form new grain boundaries (34) that, though open to the outer surface (36) of the coating (24), are free of precipitates or contain fewer precipitates (40) than the as-deposited grain boundaries (44). New grain boundaries (34) are preferably produced by causing the overlay coating (24) to recrystallize during coating deposition or after deposition as a result of a surface treatment followed by heat treatment.

    摘要翻译： β相镍铝化合物（NiAl）覆盖层（24）以及用于改变涂层（24）的晶粒结构以提高其抗氧化性的方法。 通过产生以在外涂层表面（36）处暴露的晶界（44）为特征的晶粒结构的方法沉积涂层（24）。 作为涂层（24）的合金化学的结果，晶界（44）也可以含有沉淀物（40）。 在沉积期间或之后，使覆盖涂层（24）形成新的晶粒边界（34），其尽管向涂层（24）的外表面（36）开口，但没有沉淀物或含有较少的沉淀物（40） 比沉积的晶界（44）。 优选通过在涂布沉积期间或沉积后的覆盖涂层（24）进行再结晶，然后进行热处理后的表面处理，来制造新的晶界（34）。