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US 6,605,161 B2Granted
Inoculants for intermetallic layer
AssigneeAeromet Technologies, Inc.
InventorDavid C. Fairbourn
Life of this patent
Estimating the term…
Abstract
A deposition process including applying an inoculant to at least a portion of the surface of a metal component, and then forming an intermetallic layer at the inoculant surface, such as by exposing at least the coated surface portion to a deposition environment.
Claims41
A deposition process comprising:
- applying an inoculant to at least a portion of a surface of a metal component;
- placing the metal component with the inoculant thereon in a chamber having a source of donor material independent of the component and any coating thereon;
- and
- while the metal component is in the chamber, exposing at least the inoculated surface portion and the independent source of donor material to a deposition environment in the chamber for a time to form an intermetallic layer at the inoculated surface portion including metal from the donor material therein, whereby the intermetallic layer forms at the inoculated surface portion to a thickness greater than would have been formed had the surface portion been exposed to the donor material in the deposition environment for said time without the inoculant having been first applied thereto.
1 more element
A deposition process comprising:
- placing a liquid silane onto at least a portion of a surface of a metal component and drying the liquid silane to a hard pre-coating;
- placing the metal component with the hard pre-coating thereon in a deposition environment;
- and
- while the metal component is in the deposition environment, exposing at least the surface portion with the hard pre-coating thereon to a donor material for a time to form an intermetallic layer thereat including metal from the donor material therein.
1 more element
A deposition process comprising:
- applying an aluminum-free inoculant to at least a portion of a surface of a metal component;
- placing the metal component with the aluminum-free inoculant thereon in a chamber having a source of aluminum donor material independent of the component and any coating thereon;
- and
- while the metal component is in the chamber, exposing at least the inoculated surface portion and the independent source of aluminum donor material to a deposition environment in the chamber for a time to form an intermetallic layer at the inoculated surface portion including metal from the aluminum donor material therein.
1 more element
A deposition process comprising:
- placing onto at least a surface portion of a metal component a metal-halogen Lewis acid having a metal ion desired to be incorporated into an intermetallic layer to be formed on the metal component;
- placing the metal component with the Lewis Acid thereon in a deposition environment;
- and
- while the metal component is in the deposition environment, exposing at least the surface portion with the Lewis Acid thereon to a donor material for a time to form an intermetallic layer thereat including metal from the donor material therein.
1 more element
A deposition process comprising:
- applying a metal-halogen Lewis acid to at least a portion of a surface of a metal component;
- placing the metal component with the Lewis acid thereon in a deposition environment including a donor material separate from the Lewis acid;
- and
- while the metal component is in the deposition environment, exposing at least the surface portion of the Lewis acid thereon to the separate donor material for a time to form an intermetallic layer at the surface portion including metal from the separate donor material therein.
1 more element
A deposition process comprising:
- applying a silane material to at least a portion of a surface of a metal component;
- placing the metal component with the silane material thereon in a deposition environment;
- and
- while the metal component is in the deposition environment, exposing at least the surface portion with the silane material thereon to a donor material for a time to form an intermetallic layer at the surface portion including at least metal from the donor material therein.
1 more element
A deposition process comprising:
- applying a colloidal silica to at least a portion of a surface of a metal component;
- placing the metal component with the colloidal silica thereon in a chamber having a source of donor material independent of the component and any coating thereon;
- and
- while the metal component is in the chamber, exposing at least the surface portion with the colloidal silica thereon and the independent source of donor material to a deposition environment in the chamber for a time to form an intermetallic layer at the surface portion including metal from at least the separate donor material therein.
1 more element
deposition process for a jet engine component comprising:
- selecting a jet engine component having a metal surface;
- pre-coating at least a portion of the metal surface with an inoculant;
- placing the jet engine component in a chamber having a source of donor material independent of the component and any coating thereon;
- and
- exposing at least the pre-coated surface portion and the independent source of donor material to a deposition environment in the chamber for a period of time to form an intermetallic layer at the pre-coated surface portion including metal from the donor material therein.
2 more elements
A deposition process for a jet engine component comprising:
- selecting a jet engine component having a metal surface;
- pre-coating at least a portion of the metal surface with a silane material;
- and
- forming an intermetallic layer at the pre-coated surface portion.
1 more element
A deposition process for a jet engine component comprising:
- selecting a let engine component having a metal surface;
- pre-coating at least a portion of the metal surface with a metal-halogen Lewis acid;
- and
- exposing at least the pre-coated surface portion to a deposition environment including a separate donor material for a period of time for form an intermetallic layer at the pre-coated surface portion.
1 more element
A deposition process for forming a multi-component intermetallic layer on a jet engine component comprising:
- selecting a jet engine component having a metal surface;
- selecting a metal-halogen Lewis acid having a desired functional material for inclusion in said intermetallic layer;
- applying the selected Lewis acid to at least a portion of the component metal surface;
- and
- exposing at least the surface portion with the Lewis acid thereon to a deposition environment including a separate donor material for a period of time to form a multi-component intermetallic layer including metal from the donor material at the surface portion while causing the desired functional material from the Lewis acid to disperse into the intermetallic layer.
2 more elements
A deposition process comprising:
- applying a coating consisting essentially of silane directly to a surface of a metal component;
- placing a donor material separate from the coated part in a deposition chamber;
- and
- without applying further material to the coated surface, placing at least the coated surface of the metal component in the deposition chamber spaced from the donor material.
1 more element
A deposition process comprising:
- applying a coating consisting essentially of a Lewis Acid directly to a surface of a metal component;
- placing a donor material separate from the coated part in a deposition chamber;
- and
- without applying further material to the coated surface, placing at least the coated surface of the metal component in the deposition chamber spaced from the donor material.
1 more element
Dependencies are inferred from the claim text.