# US 10,309,002 B2 · Coating methods and a template for use with the coating methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,309,002 B2 - Document ID: US10309002B2 - Status: Granted - Kind: B2 - Application number: 14/098,068 - Filed: 2013-12-05 - Published: 2016-06-09 - Granted: 2019-06-04 - Earliest claimed: 2013-12-05 - Assignees: General Electric Company - Applicants: General Electric Company - Inventors: Cem Murat Eminoglu - Web page: https://patentgrep.com/patent/US10309002B2 ## CPC - C23C 4/01: Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated - C23C 4/02: Pretreatment of the material to be coated, e.g. for coating on selected surface areas - C23C 4/129: Flame spraying - F01D 5/186: {Film cooling (F01D5/187 takes precedence)} - F01D 5/288: {Protective coatings for blades} - B23P 2700/06: Cooling passages of turbine components, e.g. unblocking or preventing blocking of cooling passages of turbine components - Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q) - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A method for coating a component is provided. The coating method includes providing a component having at least one aperture with an aperture geometry formed in a surface thereof, positioning a filler material within the at least one aperture, the filler material extending away from the surface of the component a distance greater than a reduced coating thickness and less than an applied coating thickness, applying at least one coating over the surface of the component and the filler material to form an applied coating having the applied coating thickness, removing a portion of the applied coating to provide the reduced coating thickness and expose the filler material, and removing the filler material to extend the at least one aperture having the aperture geometry through the applied coating. Another coating method and a template for use with the coating methods are also provided. ## Claims ### Claim 1 A coating method, comprising: providing a component having at least one aperture formed in a surface thereof, the aperture having an aperture geometry, the aperture geometry tapering, curving, or a combination thereof as the aperture extends into the component from the surface of the component; then positioning a filler material within the at least one aperture, the filler material extending away from the surface of the component a distance greater than a reduced coating thickness and less than an applied coating thickness, the filler material being shaped to extend the tapering, curving, or combination thereof of the aperture geometry through an applied coating; then applying at least one coating material over the surface of the component and the filler material to form the applied coating having the applied coating thickness, the applied coating adhering to the surface of the component and the filler material; then removing a portion of the applied coating to provide the reduced coating thickness and to expose the filler material; and then removing the filler material to expose the at least one aperture having the tapering, curving, or combination thereof of the aperture geometry extending through the applied coating. ### Claim 2 (depends on 1) The method of claim 1, further comprising providing a preformed filler material having a shape corresponding to the aperture geometry. ### Claim 3 (depends on 1) The method of claim 1, further comprising extruding the filler material through a template to form a shape corresponding to the aperture geometry. ### Claim 4 (depends on 1) The method of claim 1, wherein the distance further comprises between about 1% and about 80% greater than the reduced coating thickness. ### Claim 5 (depends on 1) The method of claim 1, further comprising selecting the filler material from the group consisting of water-soluble materials. ### Claim 6 (depends on 1) The method of claim 1, wherein removing the filler material comprises dissolving the filler material with a solvent. ### Claim 7 (depends on 1) The method of claim 1, wherein removing the filler material comprises degrading the filler material with a heat treatment. ### Claim 8 (depends on 1) The method of claim 1, wherein applying at least one coating material further comprises applying a bond coat and a thermal barrier coating. ### Claim 9 (depends on 1) The method of claim 1, further comprising selecting the component from the group consisting of a nozzle, a blade, a vane, a shroud, a bucket, a transition piece, a liner, and combinations thereof. ### Claim 10 (depends on 1) The method of claim 1, wherein the filler material is shaped by a template to extend the tapering, curving, or combination thereof of the aperture geometry through the applied coating, and the at least one aperture has the tapering, curving, or combination thereof of the aperture geometry extending through the applied coating as shaped by the template. ### Claim 11 (depends on 1) The method of claim 1, wherein the removing a portion of the applied coating to provide the reduced coating thickness and to expose the filler material further comprises removing a first portion of the filler material to expose a remaining portion of the filler material. ### Claim 12 (depends on 1) The method of claim 1, wherein the component is fabricated from a nickel-based superalloy. ### Claim 13 (depends on 1) The coating method of claim 1, further comprising: positioning a template over the surface of the component, the template comprising at least one template opening aligned with the at least one aperture, the at least one template opening extending the aperture geometry, wherein positioning the filler material within the at least one aperture includes positioning the filler material within the at least one template opening; and removing a removable body portion of the template without removing the filler material. ### Claim 14 (depends on 13) The method of claim 13, further comprising curing the filler material prior to removing the removable body portion of the template. ### Claim 15 (depends on 14) The method of claim 14, wherein curing the filler material comprises a curing method selected from the group consisting of heating, ultra-violet radiation, and a combination thereof. ### Claim 16 (depends on 14) The method of claim 14, further comprising melting the removable body portion of the template while curing the filler material. ### Claim 17 (depends on 13) The method of claim 13, further comprising filling at least a portion of the at least one aperture aligned with the at least one template opening. ### Claim 18 (depends on 13) The method of claim 13, further comprising conforming the removable body portion of the template to the surface of the component. ### Claim 19 (depends on 13) The method of claim 13, wherein removing the filler material further comprises a removal method selected from the group consisting of providing a solvent, providing heat, applying magnetic force, applying compressed air, and combinations thereof.