Thomas E Mantkowski

6334907, Jan 1, 2002

Oct 13, 1999

09/417468

Nripendra N. Das - West Chester OH
Thomas E. Mantkowski - Madeira OH
Jeffrey A. Conner - Hamilton OH

General Electric Company - Cincinnati OH

C23C 800

148280, 148283, 427253

A process for forming a diffusion aluminide coating on a substrate, such as a component for a gas turbine engine. The process generally entails placing the substrate in a suitable coating chamber, flowing an inert or reducing gas into and through the coating chamber, and then aluminizing the substrate using an aluminizing technique with a substantially constant aluminum activity, such as a vapor phase deposition process. During the aluminizing process, the amount of unreacted aluminum within the coating chamber is controlled by altering the flow rate of the gas through the coating chamber so that a portion of the unreacted aluminum is swept from the coating chamber by the gas. The amount of unreacted aluminum swept from the coating chamber is regulated by metering the gas flow rate in order to control the aluminizing rate and aluminum content of the resulting aluminide coating.

6440496, Aug 27, 2002

Jan 19, 2000

09/487103

Bhupendra K. Gupta - Cincinnati OH
Thomas E. Mantkowski - Madeira OH
Nripendra N. Das - West Chester OH
Raymond W. Heidorn - Fairfield OH

General Electric Company - Schenectady NY

C23C 1606

427252, 42725531, 4272557

A thermal barrier coating system and a method for forming the coating system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The coating system includes a diffusion aluminide bond coat whose oxide growth rate is significantly reduced to improve the spallation resistance of a thermal barrier layer by forming the bond coat to include a dispersion of aluminum, chromium, nickel, cobalt and/or platinum group metal oxides. The oxides preferably constitute about 5 to about 20 volume percent of the bond coat. A preferred method of forming the bond coat is to initiate a diffusion aluminizing process in the absence of oxygen to deposit a base layer of diffusion aluminide, and then intermittently introduce an oxygen-containing gas into the diffusion aluminizing process to form within the bond coat the desired dispersion of oxides. Thereafter, a ceramic layer is deposited on the bond coat to form a thermal barrier coating.

6485845, Nov 26, 2002

Jan 24, 2000

09/489719

Roger D. Wustman - Loveland OH
Jeffrey A. Conner - Hamilton OH
Jonathan P. Clarke - West Chester OH
Timothy L. Norris - Hamilton OH
Thomas E. Mantkowski - Madeira OH

General Electric Company - Schenectady NY

B32B 1504

428633, 428650, 428652, 428469, 4284722, 428632, 428697, 428699, 428701, 428702, 416241 R, 416241 B

A thermal barrier coating (TBC) system and method for forming the TBC system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The TBC system exhibits improved spallation resistance as a result of having a bond coat formed to contain a dispersion of oxide particles in its outer surface region. A method for preferentially entrapping oxide particles in a bond coat entails depositing the oxide particles on the surface of the component prior to forming the bond coat, which may be a diffusion aluminide or an aluminized overlay coating. Deposition of the bond coat causes the oxide particles to become dispersed in the outer surface region of the bond coat. A particular feature of this invention is the ability to preferentially entrap oxides of elements that are not present in the bond coat or a substrate region of the component on which the bond coat is formed.

6579567, Jun 17, 2003

Nov 13, 2000

09/711565

Nripendra N. Das - West Chester OH, 45069
Raymond W. Heidorn - Fairfield OH, 45014
Patricia A. Charles - Hamilton OH, 45011
Thomas E. Mantkowski - Madeira OH, 45243

C23C 1604

4272481, 427250, 427282

Apparatus and method to improve vapor phase diffusion coating of articles. The apparatus provides a barrier to segregate the portion of the article requiring coating from the portion of the article not requiring coating. The fixture is reusable, being unaffected by the coating gases. The fixture reduces the exposure of the coating gases with the portion of the article not requiring coating. By use of an optional seal, the portion of the article not requiring coating can be isolated from the coating gases.

6821564, Nov 23, 2004

Apr 25, 2003

10/423074

Nripendra Nath Das - West Chester OH
Raymond William Heidorn - Fairfield OH
Thomas Edward Mantkowski - Madeira OH
Patricia Ann Charles - Erie PA

General Electric Company - Schenectady NY

C23C 1600

4272481, 427220, 427221, 427250, 427282, 427503, 427504

Apparatus and method to improve vapor phase diffusion coating of articles. The apparatus provides a barrier to segregate the portion of the article requiring coating from the portion of the article not requiring coating. The fixture is reusable, being unaffected by the coating gases. The fixture reduces the exposure of the coating gases with the portion of the article not requiring coating. By use of an optional seal, the portion of the article not requiring coating can be isolated from the coating gases.

6896488, May 24, 2005

Jun 5, 2003

10/455649

Robert William Bruce - Loveland OH, US
Nripendra Nath Das - West Chester OH, US
Thomas Edward Mantkowski - Madeira OH, US

General Electric Company - Schenectady NY

F01D005/14

416241R, 427238

A bond coat process for thermal barrier coatings. The method includes, after cleaning and masking the external surface of the substrate, first applying a layer of NiCrZr alloy to the external surface of the substrate using a sputter coat or other suitable process. Aluminum is then applied to the substrate, using either a vapor phase aluminization (VPA) or chemical vapor deposition (CVD) process, wherein aluminum diffuses into the NiCrZr alloy layer wherein a diffusion layer is formed by the aluminum with the substrate material on the internal surface of the substrate. The coated substrate may then be subjected to a heat treatment in a protective atmosphere to further allow diffusion of the aluminide into the NiAlCrZr diffusion layer. The substantially Al outer layers of the NiAlCrZr diffusion layer, and the diffusion aluminide layer, will provide an aluminum source for the surface, which will oxidize to form a tightly adherent aluminum scale. The diffusion aluminide layer and the high Al portion of the NiAlCrZr diffusion layer will also function as a source of aluminum which will provide a reservoir to heal the alumina scale during operation.

7739794, Jun 22, 2010

Feb 29, 2008

12/040005

Thomas Edward Mantkowski - Madeira OH, US

General Electric Company - Schenectady NY

B21H 1/08
B23P 6/00
B23P 11/00
B23P 13/00
B23P 17/00
B60B 17/00

2989401, 29894011, 2940204, 2940205, 2940206, 2940207, 2940209, 2940211, 2940213, 2940216, 2940705, 29447, 29458, 2952514, 295 1

A method includes shrink fitting a ring member about a railroad wheel body and metallurically bonding the ring member to the railroad wheel body. A wheel assembly includes an inner portion obtained from a worn railroad wheel, a ring member disposed about the inner portion, and suitable electroplating material disposed on at least one of the faying surfaces. The wheel assembly may be heated under suitable conditions to provide diffusion bonding across interfacing faying surfaces to produce an integral wheel structure. Appropriate quenching, tempering, and finishing processes may be utilized to obtain desired properties. An article formed thereby includes an inner body portion obtained from a worn railroad wheel and a metallurically bonded outer circumferential portion. The outer portion may comprise a composition selected for desired wear characteristics.

7927656, Apr 19, 2011

Aug 31, 2006

11/469052

Thomas Edward Mantkowski - Madeira OH, US

General Electric Company - Schenectady NY

B05D 7/22

427237, 4272481

A method and apparatus for controlling the thickness of a coating deposited on internal passages of a component. The coating is a diffusion coating, preferably a diffusion aluminide coating, deposited by a vapor phase process that entails placing a component within a coating chamber so that first and second conduits fluidically communicate with first and second openings in the component. The component is heated within the coating chamber, at least one reactive vapor is generated within the coating chamber, and a carrier gas is delivered through the first conduit to force the reactive vapor to enter the internal passages through the first opening in the component and exit through the second opening. Flow of the carrier gas is then reversed so that the carrier gas is then delivered through the second conduit to force the reactive vapor to enter the internal passages through the second opening and exit through the first opening.