Thermal Spray Membrane Contact Material, Contact Member and Contact Part, and Apparatuses to Which They Are Applied




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НазваниеThermal Spray Membrane Contact Material, Contact Member and Contact Part, and Apparatuses to Which They Are Applied
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Issued between July 1, 2009 and September 30, 2009.

Prepared by Jiří Matějíček, Institute of Plasma Physics, Czech Republic; jmatejic@ipp.cas.cz and Luc Charron, Canada Institute for Scientific and Technical Information, Canada; luc.charron@cnrc-nrc.gc.ca. Adapted from QPAT by Questel, http://www.questel.com/

AU = Australian, CA = Canadian, CN = Chinese, CZ = Czech, DE = German, EP = European, JP = Japanese, RU = Russian, US = United States patents. The information has the following format: Title, Abstract, Patent number, Inventors, Company, Date of issue.


Applications


Thermal Spray Membrane Contact Material, Contact Member and Contact Part, and Apparatuses to Which They Are Applied

To provide a thermal spray membrane contact material, contact member and contact part and an apparatus to which they are applied, showing excellent seizure resistance and wear resistance even under high surface pressure/low speed sliding, high speed/high temperature sliding, or high surface pressure/high speed sliding. In a bucket connecting apparatus connecting an arm and a bucket by a work implement connecting pin, the above-mentioned work implement connecting pin comprises a base material made of steel having an axis function and a contact surface formed of a thermal spray membrane contact material film-formed on the base material, said contact surface being placed at least on a supported surface site of the work implement connecting pin relative to a bracket and on a slipping contact surface with a work implement bushing, further, said thermal spray membrane contact material being composed of a Mo metal phase, or 10 vol % or more of a Mo metal phase and a metal phase and/or alloy phase containing one or more elements selected from the group consisting of Fe, Ni, Co, Cr, Cu and Zn.

JP4289926: Takayama Takemori, Ohnishi Tetsuo, and Okamura Kazuo. Company: Komatsu Mfg Co Ltd. Issued: 20090701.

Corrosion-Resistant ABS Tone Ring

A tone ring of a vehicle anti-lock braking system of the type that is integrated into a disc brake rotor. The tone ring has a protective layer which enables it to withstand the combination of extreme heat and harsh environmental conditions to which it is exposed during operation of the vehicle. The protective layer is applied by thermally spraying a selected one of a plurality of materials, such as a nickel-based alloy, a high-chrome stainless steel, or non-ferrous materials such as an aluminum, copper-based alloys or a ceramic, on teeth of the tone ring, and without causing the protective layer to be deposited on the rotor braking surfaces. The protective layer generally prevents the formation of oxidation and corrosion byproduct layers on the teeth, to thereby maintain sensitivity for detection of teeth movement by the anti-lock braking system sensor during operation of the system.

AU2005317453: Redgrave Chris. Company: Hendrickson Int Corp. Issued: 20090709.

Method of Directly Making Rapid Prototype Tooling Having Free-Form Shape

A method and apparatus for directly making rapid prototype tooling from a computer model having a free-form shape. The method steps comprise essentially: (a) machining a soft metal tooling base so as to contour at least one free-form surface in conformity with the computer model; (b) cold-gas dynamic spraying the contoured surface to form superimposed impact welded metal particle layers, the layers consisting of at least one thermal management under-layer comprising primarily copper, and at least an outer wear resistant layer comprising primarily tool steel. This invention relates to technology for making rapid free-form tooling and more particularly to making such tooling more wear resistant with a technique that does not require melting of metal but does follow a computer model of the tooling.

DE10131657: Shaikh Furqan Z, Blair Howard Douglas, and Pan Tsung-Yu. Company: Ford Global Tech Inc. Issued: 20090709.

Surface Modification of Porous Metal Substrates Using Cold Spray

A method of preparing the surface of a porous metal substrate to receive a membrane. The method does not substantially decrease the average bulk porosity of the metal substrate. A hydrogen separation membrane supported on the porous metal substrate. A cold spray is used to reduce surface variance. Exposure to an ion beam may also be used after application on the cold spray to prepare the surface of the substrate for membrane deposition.

US7560170: Chellappa Anand. Company: Intelligent Energy Inc. Issued: 20090714.

Roll for Conveying High-Temperature Member, Its Manufacturing Method, and Thermal Spraying Material

Problem to be solved: To provide a technology for forming a highly durable coating with respect to a roll for conveyance, such as a hot run table roller, for conveying a high-temperature member, such as a hot-rolled steel material, at high speed; a method capable of forming a uniform quench-hardened layer on a roll surface, maintaining effects of the layer over a long time, inexpensively forming a sprayed coating with excellent durability and advantageously forming the sprayed coating; and a thermal spraying material used in this method. - Solution: On the surface of a roll base material for conveying the high-temperature member, the sprayed coating which contains cast iron powder in an Ni-based self-fluxing alloy matrix after remelting dispersed therein is formed.

JP4295239: Harada Yoshio and Shigemura Sadato. Company: Tocalo Co Ltd. Issued: 20090715.

Use of Spray Coatings to Achieve Non-Uniform Seal Clearances in Turbomachinery

The invention provides spray coatings to achieve circumferentially non-uniform seal clearances in turbomachines. In steam and gas turbines it is desirable to assemble the machines with elliptical seal clearances to compensate for expected casing distortion, rotor dynamics or phenomena that cause circumferentially non-uniform rotor-stator rubs. The claimed invention allows the casing hardware to be fabricated round, and a spray coating is applied to the radially inner surface such that the coating thickness varies circumferentially, providing the desired non-uniform rotor-stator clearance during assembly.

RU2362021: Turnquist Norman Arnold, Kowalczyk Mark William, and Ghasripoor Farshad. Company: General Electric. Issued: 20090720.

Sputtering Targets and Method for the Preparation Thereof

A process for the preparation of a sputtering target which comprises sub-stoichiometric titanium dioxide, TiOx, where x is below 2 having an electrical resistivity of less than 0.5 ohm.cm, optionally together with niobium oxide, which process comprises plasma spraying titanium dioxide, TiO2, optionally together with niobium oxide, onto a target base in an atmosphere which is oxygen deficient and which does not contain oxygen-containing compounds, the target base being coated with TiOx, which is solidified by cooling under conditions which prevent the sub-stoichiometric titanium dioxide from combining with oxygen.

CA2241878: Vanderstraeten Johan Emile Mar. Company: Bekaert Advanced Coatings BV. Issued: 20090721.

Method of Coating Metal Sheet

This invention relates to rolls for use in or in contact with molten metal comprising a roll drum having an outer peripheral surface and a thermally sprayed coating on the outer peripheral surface of said roll drum, said thermally sprayed coating comprising from about 66 to about 88 weight percent of tungsten, from about 2.5 to about 6 weight percent of carbon, from about 6 to about 20 weight percent of cobalt, and from about 2 to about 9 weight percent of chromium; a process for preparing the rolls; a method for forming a metal layer on a metal sheet utilizing the rolls, e.g., galvanization; and a thermal spray powder for coating the outer peripheral surface of the rolls.

EP1951932: Jarosinski William, Quets John, Wang Daming, Belov Vladimir, and Kleyman Ardy Simon. Company: Praxair S T Technology Inc. Issued: 20090722.

A Method of Manufacturing a Permanent Magnet Comprising Kinetically Spraying and Electromagnetic Devices Prepared Therewith

A method of manufacturing electric machines is disclosed which comprises of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

EP1263006: Leonardi Franco, Ginder John Matthew, and Mccune Robert Corbly. Company: Ford Global Tech LLC. Issued: 20090722.

A Method of Spray Forming an Article

A method for spraying a plurality of metal streams upon a low-heat resistant model and thereby forming a spray formed article is disclosed. Two or more spray guns are used to produce the plurality of metal streams each of which is composed of different constituent elements. The spray conditions are controlled in such a manner that the individual metal droplets forming the metal streams remain substantially segregate so that the resulting spray formed article is composed at least partially of a pseudo-alloy.

EP1285975: Grinberg Grigoriy, Shade Matthew M, Collins David Robert, and Allor Richard L. Company: Ford Global Tech Inc. Issued: 20090729.

Method for Manufacturing Twin-Screw Cylinder

Problem to be solved: To provide a method for manufacturing a twin-screw cylinder by which a dense coating layer having high joining force can be easily deposited onto the internal surface of the cylinder even in the case of a cylinder with relatively large diameter. - Solution: The method for manufacturing the twin-screw cylinder comprises steps of: inserting a heating device into a cylinder hole having openings at both ends in a longitudinal direction of a base material for cylinder via at least either of the openings to preheat the internal surface of the cylinder; inserting a thermal spraying machine via the opening into the preheated cylinder hole to coat the internal surface of the cylinder with alloy powder by a thermal spraying method; and subjecting the base material for cylinder on which a spray deposit is formed to vacuum remelting treatment to diffusion- join the spray deposit to the internal surface of the cylinder.

JP4303447: Motogami Tsutomu, Takemura Takashi, and Ohara Atsuna. Company: Kobe Steel Ltd, Tocalo Co Ltd. Issued: 20090729.

Sputtering Target Producing Few Particles, Backing Plate Provided With the Target, and a Method of Producing the Target

A sputtering target producing few particles, a backing plate or a sputtering apparatus, and a sputtering method producing few particles. An arc-spraying coating film and a plasma-spraying coating film over the former are formed on the sputtering target, a backing plate, or another surface in the sputtering apparatus, where an unwanted film might be formed. Thus a deposit is prevent from separating/flying from the target, backing plate, or another surface where an unwanted film might be formed in the sputtering apparatus.

EP1312695: Okabe T, Yamakoshi Y, and Miyashita H. Company: Nikko Materials Co Ltd, Nippon Mining Co. Issued: 20090729.

Method for Overcladding an Optical Fiber Preform

Method for overcladding an optical fibre preform with a given target diameter (D0) of the final preform comprises providing a primary preform to be overcladded, and successively depositing first overcladding layers by projecting and vitrifying silica particles on the primary preform moving in relative translation with a plasma torch. Each first overcladding layer has a given constant thickness (d) and is deposited at a given, constant silica particle flow rate and at a given, constant translation speed. The method also comprises the detection of a preform diameter (D1) greater than a given threshold (S) and the depositing of a last overcladding layer having the remaining required thickness (D0 -D1) at a silica particle flow rate maintained constant and at a reduced translation speed. The inventive method enables a preform to be overcladded efficiently with improved yield and high quality.

EP1870382: Petitfrere Emmanuel. Company: Draka Comteq. Issued: 20090729.

Piezo-Electric Substrate and Manufacturing Method of the Same

A piezo-electric substrate is mainly comprised of a base material, and a film formed on one main surface of the base material. In the base material, the main surface on which the film is formed is a roughed main surface. The piezo-electric substrate is obtained by forming the film comprised of a material with a coefficient of linear expansion smaller than a coefficient of linear expansion of the base material on the roughened main surface using a thermal spraying method.

US7569976: Tamura Noboru, Ichikawa Nakaba, Takabatake Takeshi, and Yasuda Kaname. Company: Koike Co Ltd, Tocalo Co Ltd. Issued: 20090804.

Al2o3/Al-Si-Cr Composite Coatings and Preparation Method Thereof

Invented has publicized one kind of Al 2O3/Al-Si-Cr compound coating, as well as used the low pressure 30-40x103Pa plasma spray coating craft to prepare the Al2O3/Al-Si-Cr compound coating in the Nb-24Ti-16Si-6Al-6Cr-2Hf substrate the method. States the Al2O3/Al-Si-Cr compound coating is composed of Al2O3 coating and the Al-Si-Cr mix level, Al2O3 coating in the Al-Si-Cr mix level and between the Nb-24Ti-16Si-6Al-6Cr-2Hf substrate, Al2O3 coating thickness is 50-200 m, Al-Si-Cr mix level thickness is 50-200 m; States in the Al2O3/Al-Si-Cr compound coating the Al-Si-Cr mix level to contain Cr(Si, Al)2, Al, Si three-phase, 1000-1250 C will oxidize 100h in the high temperature later to be able to form continuously, compact Al2O3 and SiO2 mix oxide skin; States Al2O3 coating to be able to prevent between the Al-Si-Cr mix coating and the substrate proliferation effectively mutually, thus enhanced the coating to continue the oxidation resistance life.

CN100522607: Chungen Zhou, Rui Cai, Dengzun Yao, Hu Zhang, and Huibin Xu. Company: Univ Bei Hang. Issued: 20090805.

Stretching Roller for Producing Synthetic Fiber, Method for Producing the Same and Method for Producing Synthetic Fiber by Using the Same

Problem to be solved: To provide a stretching roller for producing a synthetic fiber, improving a low friction property and abrasion resistance and reducing the occurrence of fluffs and single yarn-cuttings, a method for producing the same and a method for producing the synthetic fiber. - Solution: This stretching roller is obtained by forming a cermet layer by thermally spraying a tungsten carbide composite material on the surface of a roller basic material. The surface coarseness prescribed by JIS-B0602:2001 of the surface of the cermet layer is 0.3-5 .mu.m arithmetic average coarseness Ra, and an areal ratio (B/A) is 15-35 % by taking A as a triangular total area surrounded by a straight line (a) connecting coordinate points (0, 0) and (100, 100), a line with 0 % load length ratio and a line with 50 % cut level in the rectangular coordinates of the load length ratio (%) showing a relative load length Rmr with the cutting level (%), and B as a total area surrounded by the line (a) and a relative load length curve (b). By using the stretching roller, the synthetic fiber is produced.

JP4307196: Fujii Takashi, Wada Naotake, Matsuura Masaki, and Kubo Shinichi. Company: Tocalo Co Ltd, Toray Industries. Issued: 20090805.

Non-Aqueous Electrolyte Battery and Method of Manufacturing the Same

A non-aqueous electrolyte battery and a method of manufacturing the battery are provided. The non-aqueous electrolyte battery has a positive electrode including a positive electrode active material-layer stack containing a plurality of different positive electrode active materials and formed on a positive electrode current collector surface, a negative electrode including a negative electrode active material layer, and a separator interposed between the electrodes. The positive electrode active material-layer stack includes two or more layers respectively containing different positive electrode active material components, and of the two or more layers, the layer nearer the positive electrode current collector is formed by coating the collector with a positive electrode active material having the highest resistance increase rate and a conductive agent contained in that positive electrode active material by cold spraying. A non-aqueous electrolyte battery and a method of manufacturing the battery are provided.

US7572548: Imachi Naoki, Yu Denis Yau W, and Fujitani Shin. Company: Sanyo Electric Co. Issued: 20090811.

Steam Turbine Valve Manifold Stellite Alloy Plasma Spray Welding Method and Equipment

The disclosed spray welding method and device is disclosed for alloy used on steam turbine valve cover. As the target is circular, has large area and lots of weld paths, it should use mobile-weld path (multi-weld path) to spray weld the outside surface with welding layer thickness within a proper range. Wherein, controlling reasonably all of the start-end lapping quantity, oscillating amplitude, water temperature and pressure, working argon gas, feeding powder, protective argon gas flow, transfer arc current, and the welding speed; adjusting opposite destress parameters, and ensuring to meet design request.

CN100526512: Hu Yuncheng Bao. Company: Dongfang Steam Turbine Works. Issued: 20090812.

Process for Hot Spraying of Rotating Parts

A hot spray method for the rotating workpiece includes such steps as applying a prestress to the surface of workpiece, washing for removing oil, roughening the surface, spraying NiAl, NiCr or FeCrAl to form a basic layer, spraying Mo, 3Cr13 or 2Cr13 to form a working layer, and high-speed electric arc spray. It can improve the fatigue strength.

CN100528379: Hu Yong, Tang Yuhui, and Wang Xilin. Company: Shanghai Inst of Iron & Steel. Issued: 20090819.

Die Coatings for Gravity and Low Pressure Die Casting

A die coating for use on the surface of a metal mould or die component contacted by molten metal in low pressure or gravity die casting, said die coating including a porous layer of ceramic material produced by co-deposition, using a thermal spraying procedure, of a powder of said ceramic material and a powder of a suitable organic polymer material and, after the co-deposition, heating of said polymer material to cause its removal.

EP1171253: Jahedi Mahnaz, Giannos Mary, and Gulizia Stefan. Company: Cast Centre Ltd. Issued: 20090826.

Orthodontic Appliances Having Improved Bonding Characteristics

Orthodontic appliances having improved bonding characteristics and methods of making such orthodontic appliances are disclosed. The appliances to which the present invention is applicable have a metal bonding base and tooth contact surface. Primary mechanical interlock retention means or surface is applied to the tooth contact surfaces. The primary retention surface may be 1) a mesh, 2) a layer of metallic or non-metallic particles (such as spheres, rods, shards, etc.), or 3) grooves, including undercuts, formed in the tooth contact surface. The appliances preferably further comprise secondary mechanical bond strength enhancement means or treatment. Suitable secondary enhancement treatments include 1) surface roughening (e.g., ion bombardment or other etching processes), 2) particles on the order of 5-200m flame spray coated on the primary retention surface, and 3) a chemically activatable material, such as SiO2 deposited on the primary retention surface. Chemical activation may also be used to activate the chemically activatable material, such as silanation of SiO2. Orthodontic appliances having improved bonding characteristics and methods of making such orthodontic appliances are disclosed.

DE4336913: Farzin-Nia Farrokh. Company: Ormco Corp. Issued: 20090827.

Thermal Spray Compositions for Abradable Seals

A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.

US7582362: Fiala Petr, Chilkowich Anthony P, and Hajmrle Karel. Company: Sulzer Metco Canada Inc. Issued: 20090901.

Peek Coated Seal Surfaces

A sealing apparatus is combined in a housing, such as a motor protector housing, having a hole extending therethrough. A shaft is movably disposed through the hole. A lip is disposed about the shaft and a ring is movably disposed about the shaft between the section and the lip. Sealing surfaces exist on opposite sides of the ring and on corresponding portions of the lip and the section. A polymeric coating is applied to at least one of the sealing surfaces. The polymeric coating may include a PEEK composite applied by an HVOF thermal spray process. A compressed spring assembly may be utilized to ensure a continuous seal. The present invention relates generally to polymeric coated bearing surfaces, and particularly to bearing surfaces in a submergible pumping system in which a polymeric material, such as a PEEK composite material, is bonded to the bearing surface.

US7581734: Mcleod Christopher R. Company: Schlumberger Technology Corp. Issued: 20090901.

Method for Producing a Layer System Comprising a Metallic Carrier and an Anode Functional Layer

The aim of the invention is to produce complete high temperature fuel cells by means of thermal injection processes (e.g. atmospheric plasma injection, vacuum plasma injection, high speed flame injection). The production method is especially simplified and is economical by virtue of the fact that the carrier substrate is also produced on a base with the aid of a thermal injection method. The base or an intermediate layer placed thereon can be advantageously dissolved or decomposed such that the carrier substrate provided with layers arranged thereon can be separated in a very simple manner from the base which becomes unnecessary. Said method advantageously enables the production of all layers of a high temperature fuel cell, exclusively with the aid of a thermal injection method.

US7582374; AU2004217835: Vassen Robert, Hathiramani Dag, Buchkremer Hans Peter, Tietz Frank, Doering Jens-Erich, Siegert Roberto, Traeger Franziska, and Stoever Detlev. Company: Forschungszentrum Juelich Gmbh. Issued: 20090901; 20090820 .

Electrical Contact Connection and Method for Creating One Such Contact Connection

In order to make it possible to produce a secure and permanent contact connection between an electrical conductor made from a soft material, in particular an aluminum conductor, and a contact element made from a harder material, the conductor is encapsulated at least partially in a contact region by an electrically conductive material. The electrically conductive material is harder than the soft material of the conductor. The electrically conductive material is applied with the aid of a thermal spraying process, with the result that there is a pressure-free electrical connection between the soft material and the sprayed-on material. Electrical contact is made with the contact element indirectly via the sprayed-on material. The thermal encapsulation by the spraying in the contact region makes it possible for a reliable electrical contact to be made even in the case of soft materials having a tendency towards cold flow.

EP1759439: Reichinger Gerhard. Company: Leoni AG . Issued: 20090930.

Method of Producing (Feal+Cr7C3)/(Gamma Fe, Ni) Composite Coating

The invention provides a preparation method of composite coating of (FeAl+Cr7C3)/Gamma-(Fe, Ni). Low carbon steel is taken as base material and put on a working table for plasma cladding and the distance between the low carbon steel and plasma moment is 27-30mm; on the basis of Fe-based alloy powder system, Al2O3 powder with a weight percentage of 10-15 percent is ball-milled for 30-60 min to lead the powder to be fully mixed and produce coating material which is then put in a powder feeder of a plasma cladding device, so as to prepare plasma cladding coating. The technological parameters of the plasma cladding are: 250-300A of working current, 350-400mm/min of scanning speed, 0.4-0.8m3/h of powder blower gas (Ar), 0.4-0.8m3/h of plasma gas (Ar) and 0.4-0.8m3/h of protection gas (Ar). The coating prepared by the method of the invention has the advantages of small grain size, uneven composition and high coating hardness with good wear-resisting and anti-high temperature performances.

CN100535190: Dongbai Sun, Limin Zhang, Hongying Yu, Huimin Meng, Zishuan Fan, and Xudong Wang. Company: Univ Beijing Science & Tech. Issued: 20090902.

Method for Coating a Cylinder Sleeve

The invention relates to a method for coating a cylinder sleeve consisting of an iron-based material. A first layer and a second layer made of a zinc alloy are injected onto the outer surface using a thermal injection method. A good metallic connection between the cylinder sleeve and the cylinder crankcase, wherein the cylinder sleeve is poured, is produced by using alloyed or unalloyed copper for the first layer and by using a zinc-aluminum-alloy for the second layer.

EP1896626: Bucher Gerhard. Company: Mahle Int Gmbh. Issued: 20090909.

Thermal barrier coatings and bondcoats


Gas Turbine Nozzle Segment and Process Therefor

A gas turbine engine nozzle segment and process for producing such a nozzle segment to exhibit improved durability and aerodynamic performance. The process produces a nozzle segment having at least one vane between and interconnecting a pair of platforms. The nozzle segment is cast from a gamma prime-strengthened nickel-base superalloy, on whose surface is thermal sprayed an environmental coating formed of a MCrAlX-type coating material. The surface of the environmental coating is then worked to cause the coating to have a surface finish of less than 2.0 micrometers Ra. Cooling holes are then drilled in the nozzle segment, after which an oxidation-resistant coating is applied on the smoothed surface of the nozzle segment so as to maintain an outermost surface on the nozzle segment having surface finish of less than 2.0 micrometers Ra.

EP1803896: Farmer Andrew David, Nagaraj Bangalore Aswatha, Lu Wenfeng, Lee Ching-Pang, and Guentert Joseph M. Company: General Electric (US). Issued: 20090701.

Member to Be Exposed to High Temperature, and Its Manufacture

Problem to be solved: To obtain a member to be exposed to high temperature, which is free from degradation of high temperature strength attendant on deficiency of Ni and Cr due to diffusion of undercoat components, cracking and local breakage caused by thermal fatigue, reduction in adhesion of inner film, dissipation of a heat shielding action of topcoat and peeling of the topcoat and has prolonged service life. - Solution: An undercoat of chromium carbide type cermet, composed essentially of Cr2C3 and having high thermal conductivity in addition to excellent adhesion and heat resistance, is applied by a thermal spraying process to the high-temperature-side surface of a base material made of heat resistant alloy in which one side is forcedly cooled and the other side is exposed to high temperature. Further, a topcoat of ZrO2 ceramics or MCrAlX alloy is formed on the above, by which a composite hot-melt-spray-coating is formed.

JP4313459: Harada Yoshio, Tani Kazumi, and Mifune Noriyuki. Company: Tocalo Co Ltd. Issued: 20090812.

Multilayer Bond Coat for a Thermal Barrier Coating System and Process Therefor

A method of depositing a bond coat of a thermal barrier coating (TBC) system for components designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method yields a dense, bi-layer bond coat having an adequate surface roughness for adhering a plasma-sprayed ceramic layer. The method generally entails depositing a first bond coat layer using a high velocity oxy-fuel (HVOF) technique employing a relatively fine metallic powder having a relatively narrow size distribution. Following heat treatment, a second bond coat layer is deposited on the first bond coat layer by air plasma spraying (APS) a relatively coarser metallic powder of particles having a relatively broader size distribution. The resulting second bond coat layer is characterized by a macro-surface roughness of about 450 to about 750 microinches Ra. Following a second heat treatment, the ceramic layer is deposited that adheres to the bond coat through mechanical interlocking with the rough surface of the second coat layer. The present invention relates to protective coatings for components exposed to high temperatures, such as components of a gas turbine engine. More particularly, this invention is directed to a process for forming a bond coat of a thermal barrier coating system, and specifically a dense multilayer bond coat having a desirable level of surface roughness to promote mechanical interlocking between the bond coat and a thermal barrier coating deposited on the bond coat.

CZ300909: Zheng Xiaoci. Company: General Electric. Issued: 20090909.

Applying Bond Coat to Engine Components Using Cold Spray

A process for applying a coating to a component used in an engine is provided. The process includes the steps of providing a component with at least one surface to be coated, and depositing at least one layer of powder coating material onto the at least one surface using a non-oxidizing carrier gas so that the powder coating material plastically deforms without melting and bonds to the at least one surface upon impact with the at least one surface. The process of the present invention has particular utility in applying bond coats to airfoil portions of turbine blades or vanes and to applying bond coats to combustion chamber liners.

EP1705266: Debiccari Andrew, Freling Melvin, and Haynes Jeffrey D. Company: United Technologies Corp. Issued: 20090902.

Spraying systems and methods

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