Richard John Grylls

US Patent:

6485792, Nov 26, 2002

Filed:

Aug 23, 2000

Appl. No.:

09/644491

Inventors:

Richard John Grylls - Albuquerque NM
Joseph David Rigney - Milford OH
Matthew David Saylor - Blanchester OH
Theodore Robert Grossman - Hamilton OH

Assignee:

General Electric Company - Schenectady NY

International Classification:

C23C 406

US Classification:

427456, 4273768, 4273837

Abstract:

A method for applying substantially stoichiometric NiAl to the surface of a superalloy substrate. These coatings are applied to substrates subjected to high temperatures and thermal cycling by providing a powder of the substantially stoichiometric material with the desired minor additions of rare earth elements, Cr or Zr. The coatings are applied by a thermal spray process utilizing hydrogen as a fuel while generating a highly reducing flame. The thermal spray method melts the powder and directs it onto the surface of the turbine component that is to be coated. The powder size is carefully controlled to prevent oxidation of the powder while providing a controlled surface finish. The surface roughness of the bond coat is further mechanically worked to a predetermined surface finish prior to application of the ceramic thermal barrier layer by a PVD method. Thermal barrier systems applied using these carefully controlled predetermined parameters provide outstanding resistance to TBC spallation under conditions of high cyclic stresses.

US Patent:

6502304, Jan 7, 2003

Filed:

May 15, 2001

Appl. No.:

09/855444

Inventors:

Joseph David Rigney - Milford OH
William Scott Walston - Mason OH
Richard John Grylls - Albuquerque NM

Assignee:

General Electric Company - Schenectady NY

International Classification:

B23P 1500

US Classification:

2988921, 2988922

Abstract:

Optimized tip performance for turbine airfoils is obtained through a sequenced manufacturing process. The turbine airfoils are assembled into the dovetail slots of a turbine disk. The tips of the turbine airfoils assembled in the turbine disk are then measured to determine the turbine airfoils that do not have adequate tip clearance. The tips of those turbine airfoils that do not have adequate tip clearance are then machined to obtain adequate tip clearance. Once all the turbine airfoils have adequate tip clearance, environmental coatings and/or thermal barrier coatings are applied to the blade tips.

US Patent:

6616410, Sep 9, 2003

Filed:

Nov 1, 2001

Appl. No.:

10/041072

Inventors:

Richard John Grylls - Albuquerque NM
Joseph David Rigney - Milford OH
Melvin Robert Jackson - Niskayuna NY

Assignee:

General Electric Company - Schenectady NY

International Classification:

F01D 528

US Classification:

416224, 416241 R, 4151734, 298892, 228214, 2282241

Abstract:

The present invention provides for a squealer tip to include some proportion of a highly oxidation-resistant material, and a method for casting same, such that if any environmental coating were removed, the tip would retain some increased level of environmental resistance. The oxidation-resistant material optionally may also be a high abrasion resistance material, such that recession of the tip due to rubbing against a stator would be reduced. In a preferred embodiment, an abrasion-resistant and/or oxidation-resistant material is placed and suitably anchored into the tip region of a wax precursor used to cast a turbine airfoil. During the casting operation, the abrasion-resistant and/or oxidation-resistant material is not completely melted. As the alloy used to form the majority of the turbine blade solidifies, the abrasion and/or oxidation resistant material is incorporated into the turbine airfoil by the solidification of the alloy around it.

US Patent:

6720088, Apr 13, 2004

Filed:

Feb 5, 2002

Appl. No.:

09/683700

Inventors:

Ji-Cheng Zhao - Latham NY
Melvin Robert Jackson - Niskayuna NY
Richard John Grylls - Albuquerque NM
Ramgopal Darolia - Westchester OH

Assignee:

General Electric Company - Niskayuna NY

International Classification:

B32B 1500

US Classification:

428615, 148516, 148527, 148408, 148409, 148410, 148419, 148425, 148426, 148428, 148429, 148430, 148442, 416241 R, 420435, 420437, 420441, 420442, 420444, 420445, 420456, 420460, 420462, 420580, 420588, 428621, 428622, 428627, 428632, 428660, 428668, 428670, 428680, 428686, 428926, 428937, 428938, 428941

Abstract:

A group of alloys suitable for use in a high-temperature, oxidative environment, a protective coating system comprising a diffusion barrier that comprises an alloy selected from the group, an article comprising the diffusion barrier layer, and a method for protecting an article from a high-temperature oxidative environment comprising disposing the diffusion barrier layer onto a substrate are presented.

US Patent:

6998151, Feb 14, 2006

Filed:

May 10, 2002

Appl. No.:

10/143662

Inventors:

Richard Grylls - Albuquerque NM, US
Theodore Robert Grossman - Hamilton OH, US

Assignee:

General Electric Company - Cincinnati OH

International Classification:

B05D 3/02
B05D 1/36
C23C 4/08
C23C 28/00
C25D 15/00

US Classification:

427191, 427192, 4273831, 427404, 427405, 427437, 427438, 427456, 205109, 205118, 205170, 205176, 205178, 205180, 205181, 205191

Abstract:

The present invention provides a method to coat an article using a plating process, either electroless or electrolytic, whereby nickel is plated on the article using a solution that includes a suspension of powders or containing one or more of the following elements: Ni, Cr, Al, Zr, Hf, Ti, Ta, Si, Ca, Fe, Y and Ga. Optionally, the coating is then heat treated at a temperature above about 1600 F. for an effective amount of time to allow to homogenize the coating by allowing effective interdiffusion between the species. The level of aluminum may be altered to produce a coating of the predominantly β phase of the NiAl alloy composition. Optionally, a TBC layer is applied over the predominantly β phase NiAl alloy composition metallic bond coat.

US Patent:

7879394, Feb 1, 2011

Filed:

Jun 1, 2007

Appl. No.:

11/757139

Inventors:

David M. Keicher - Albuquerque NM, US
Lucas B. Brewer - Albuquerque NM, US
Richard John Grylls - Albuquerque NM, US

Assignee:

Optomec, Inc. - Albuquerque NM

International Classification:

B05D 7/22
B05D 3/06
B05C 19/00
B05C 11/00

US Classification:

427236, 427554, 4274271, 427180, 4274273, 118308, 118641, 118306, 118317, 118323

Abstract:

Method and apparatus for depositing material in hard to reach locations of a workpiece. An elongated member is inserted in an opening. The member transports a laser beam from a fiber laser and material, preferably in powder form, to the desired location. The material is deposited on the workpiece and the laser beam contacts the material. The method and apparatus may be used to manufacture a part or to repair an existing part.

US Patent:

20100021289, Jan 28, 2010

Filed:

Aug 29, 2005

Appl. No.:

11/214292

Inventors:

Richard John Grylls - Albuquerque NM, US
Theodore Robert Grossman - Hamilton OH, US

Assignee:

GENERAL ELECTRIC COMPANY - Schenectady NY

International Classification:

F01D 9/02
F01D 5/18

US Classification:

415177, 416241 R

Abstract:

The present invention provides a coated article made using a plating process, either electroless or electrolytic, whereby nickel is plated on the article using a solution that includes a suspension of powders or containing one or more of the following elements: Ni, Cr, Al, Zr, Hf, Ti, Ta, Si, Ca, Fe, Y and Ga. Optionally, the coating is then heat treated at a temperature above about 1600.degree. F. for an effective amount of time to allow to homogenize the coating by allowing effective interdiffusion between the species. The level of aluminum may be altered to produce a coating of the predominantly beta phase of the NiAl alloy composition. Optionally, a TBC layer is applied over the predominantly beta phase NiAl alloy composition metallic bond coat.