Coating processes – Solid particles or fibers applied – Interior or hollow article coating
Reexamination Certificate
1999-10-04
2001-10-09
Beck, Shrive P. (Department: 1762)
Coating processes
Solid particles or fibers applied
Interior or hollow article coating
C427S192000, C427S226000, C427S230000, C427S239000, C427S376800, C427S383700
Reexamination Certificate
active
06299935
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates generally to metallurgical processes. More specifically, it is directed to coating processes for substrates such as turbine engine components.
A variety of specially-formulated coatings is often used to protect metal parts that are exposed to high temperatures, e.g., metal parts made from superalloys. For example, aluminide coatings are often used to improve the oxidation- and corrosion-resistance of superalloy materials. In aluminide coatings, the aluminum forms an aluminum oxide (alumina) film on its surface, which functions as a barrier to further oxidation. Such coatings may also serve as a bond coat between the superalloy substrate and a thermal barrier coating (TBC).
Several processes for depositing aluminide layers are available for both newly formed components and components under repair. Such processes include vapor phase deposition techniques and what is known in the art as the ‘pack cementation process.’ While vapor phase techniques are suitable for coating internal and external surfaces of a component, additional processing complexity may be an issue for certain applications. While the pack cementation process is effective at coating internal surfaces of a component, this process is expensive, time consuming, and requires highly specialized equipment, generally requiring the component to be shipped from the job site to an outside service provider in the case of components under repair.
Accordingly, a need exists in the art for further improved and alternative methods for forming aluminide coatings.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a method for coating a surface of a substrate includes providing a substrate having a surface, coating the surface with a foam suspension containing a powder suspended in a foam to form a coating on the surface, wherein the coating has an activator; and subjecting the substrate to a diffusion treatment.
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Cartier, Jr. Thomas Joseph
Park Dong-Sil
Pfaendtner Jeffrey Allan
Rigney Joseph David
Ruud James Anthony
Beck Shrive P.
Crockford Kirsten A.
DiConza Paul J.
General Electric Company
Ingraham Donald S.
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