# US 8,541,069 B2 · Method of guided non-line of sight coating

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- Number: US 8,541,069 B2
- Document ID: US8541069B2
- Status: Granted
- Kind: B2
- Application number: 13/083,727
- Filed: 2011-04-11
- Published: 2012-10-11
- Granted: 2013-09-24
- Earliest claimed: 2011-04-11
- Assignees: United Technologies Corporation
- Applicants: Michael D. Greenberg; Benjamin J. Zimmerman
- Inventors: Michael D. Greenberg; Benjamin J. Zimmerman
- Web page: https://patentgrep.com/patent/US8541069B2

## CPC

- C23C 14/28: by wave energy or particle radiation (C23C14/32 - C23C14/48 take precedence)
- C23C 14/044: {using masks to redistribute rather than totally prevent coating, e.g. producing thickness gradient}
- C23C 14/228: {Gas flow assisted PVD deposition}
- 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)

## Abstract

A method for applying a vapor deposition coating onto a substrate with a non line of sight or limited line of sight is disclosed. A vapor stream is provided in a chamber that is below atmospheric pressure. The vapor stream is impinged with a working gas that provides a flow that transports the vapor stream. The flow of the working gas is modified with a physical object that directs the flow to achieve a desired coating on the substrate.

## Claims

### Claim 1

A method for applying a coating on substrate, the method comprising:
placing the substrate into a chamber;
impinging an evaporant source in the chamber with a beam to generate an evaporated vapor cloud in the chamber; and
presenting a carrier gas stream to the chamber to disperse the evaporated vapor cloud;
deflecting the evaporated vapor cloud being moved by the carrier gas stream, wherein the deflecting is done with at least one vapor cloud modifier that disrupts a flow of the carrier gas stream that prevents an area of the substrate from being coated, and wherein the evaporated vapor cloud at least partially coats at the substrate.

### Claim 2 (depends on 1)

The method of claim 1 wherein the at least one vapor cloud modifier is positioned to enhance the coverage of an area of the substrate by the evaporated vapor cloud.

### Claim 3 (depends on 1)

The method of claim 1 wherein the at least one vapor cloud modifier comprises an airfoil.

### Claim 4 (depends on 1)

The method of claim 1 wherein the substrate contains a non line of sight feature.

### Claim 5 (depends on 4)

The method of claim 4 wherein the substrate is a multi-airfoil vane segment for a gas turbine engine.

### Claim 6 (depends on 5)

The method of claim 5 wherein the coating is a thermal barrier coating.

### Claim 7

A method for applying vapor deposition onto a substrate with a non line of sight or limited line of sight comprising:
providing a vapor stream in a chamber, wherein the chamber is below atmospheric pressure;
impinging the vapor stream with a working gas that provides a flow that transports the vapor stream;
modifying a flow of the working gas with a physical object that directs the flow to achieve a desired coating on the substrate, wherein the physical object that directs the flow prevents an area of the substrate from being coated.

### Claim 8 (depends on 7)

The method of claim 7 wherein the physical object that directs the flow enhances the coverage of an area of the substrate by the vapor stream being carried by the working gas.

### Claim 9 (depends on 7)

The method of claim 7 wherein the physical object has an airfoil shape.

### Claim 10 (depends on 7)

The method of claim 7 wherein the substrate is a multi-airfoil vane segment for a gas turbine engine.

### Claim 11 (depends on 10)

The method of claim 10 wherein the coating is a thermal barrier coating.