US4291089A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite powders sprayable to form abradable seal coatings
Assignee: Westaim Corp
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Filing: 1979-11-06
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Granted: 1981-09-22
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Expires: 1999-11-06
Abstract
Abstract A composite powder sprayable by thermal spraying onto a substrate to form an abradable seal coating with suitable strength and erosion resistance. Each powder particle has a core of non-metallic solid material surrounded by a layer of metallic material selected from the group consisting of nickel and nickel alloys. At least about 95% of the particles have a size less than about 150 microns, at least about 50 to about 90% of the particles have a size greater than about 75 microns, and less than about 10% of the particles have a size less than about 45 microns.
Inventors
- 👤 Emilija Adamovic
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 21:05
CPC Classifications
F; F01; F01D; F01D11/00; F01D11/08; F01D11/12; F01D11/122; B; B22; B22F; B22F1/00; B22F1/18; C; C23; C23C; C23C4/00; C23C4/04; C23C4/06; Y; Y02; Y02T; Y02T50/00; Y02T50/60; Y10; Y10T; Y10T428/00; Y10T428/25; Y10T428/252; Y10T428/256; Y10T428/26; Y10T428/268; Y10T428/29; Y10T428/2982; Y10T428/2991; Y10T428/2993
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
106 words
A composite powder sprayable by thermal spraying onto a substrate to form an abradable seal coating with suitable strength and erosion resistance, said powder comprising particles each having a core of non-metallic solid material surrounded by a layer of metallic material selected from the group consisting of nickel and nickel alloys, at least about 95% by weight of the particles having a size less than about 150 microns, at least about 50 to about 90% by weight of the particles having a size greater than about 75 microns; and less than about 10% by weight of the particles having a size less than about 45 microns.
Claim 2
Dependent Claim
106 words
A composite powder sprayable by thermal spraying onto a substrate to form an abradable seal coating with suitable strength and erosion resistance, said powder comprising particles each having a core of non-metallic solid material surrounded by a layer of metallic material selected from the group consisting of nickel and nickel alloys, at least about 95% by weight of the particles having a size less than about 150 microns, at least about 50 to about 90% by weight of the particles having a size greater than about 75 microns; and less than about 10% by weight of the particles having a size less than about 45 microns.
Claim 3
Dependent Claim
28 words
A composite powder according to claim 1 wherein at least about 55 to about 65% by weight of the particles have a size greater than about 75 microns.
Claim 4
Dependent Claim
30 words
A composite powder according to claim 1 wherein the ratio of the metallic material to non-metallic material by weight is in the range of from about 78:22 to about 90:10.
Claim 5
Dependent Claim
29 words
A composite powder according to claim 3 wherein the ratio of metallic material to non-metallic material by weight is in the range of from about 80:20 to about 82:18.
Claim 6
Dependent Claim
14 words
A composite powder according to claim 1 wherein the metallic material is nickel-chromium-aluminum alloy.
Claim 7
Dependent Claim
31 words
A composite powder according to claim 5 wherein the nickel-chromium-aluminum alloy contains from about 4 to about 8% by weight chromium and from about 2 to about 6% by weight aluminum.
Claim 8
Dependent Claim
31 words
A composite powder according to claim 6 wherein the nickel-chromium-aluminum alloy contains from about 4.5 to about 6% by weight chromium, and from about 3 to about 5% by weight aluminum.
Claim 9
Dependent Claim
20 words
A composite powder according to claim 5 wherein the nickel-chromium-aluminum alloy also contains up to about 1% by weight silicon.
Claim 10
Dependent Claim
20 words
A composite powder according to claim 5 wherein the nickel-chromium-aluminum alloy also contains up to about 1% by weight iron.
Claim 11
Dependent Claim
17 words
A composite powder according to claim 1 wherein each particle has a core of heat insulating material.
Claim 12
Dependent Claim
16 words
A composite powder according to claim 10 wherein each particle has a core of ceramic material.
Claim 13
Dependent Claim
15 words
A composite powder according to claim 11 wherein each particle has a core of bentonite.
Claim 14
Dependent Claim
15 words
A composite powder according to claim 11 wherein each particle has a core of rhyolite.
Claim 15
Dependent Claim
16 words
A composite powder according to claim 1 wherein each core consists of a single core particle.
Claim 16
Dependent Claim
25 words
A composite powder according to claim 1 wherein less than about 5% by weight of the particles have a size less than about 45 microns.
Claim 17
Dependent Claim
112 words
An abradable seal assembly comprising an abradable seal coating carried by a substrate, said abradable seal coating having been deposited on the substrate by thermal spraying a composite powder comprising particles each having a central core of non-metallic solid material surrounded by a layer of metallic material selected from the group consisting of nickel and nickel alloys, at least about 95% by weight of the particles having a size less than about 150 microns, at least about 50 to about 90% by weight of the particles having a size greater than about 75 microns, and less than about 10% by weight of the particles having a size less than about 45 microns.
Claim 18
Dependent Claim
112 words
An abradable seal assembly comprising an abradable seal coating carried by a substrate, said abradable seal coating having been deposited on the substrate by thermal spraying a composite powder comprising particles each having a central core of non-metallic solid material surrounded by a layer of metallic material selected from the group consisting of nickel and nickel alloys, at least about 95% by weight of the particles having a size less than about 150 microns, at least about 50 to about 90% by weight of the particles having a size greater than about 75 microns, and less than about 10% by weight of the particles having a size less than about 45 microns.
Claim 19
Dependent Claim
46 words
An abradable seal assembly according to claim 16 wherein said abradable coating has been deposited on the substrate by thermal spraying a composite powder having from at least about 55 to about 65% by weight of the particles with a size greater than about 75 microns.
Claim 20
Dependent Claim
50 words
An abradable seal assembly according to claim 16 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the ratio of metallic material to non-metallic material by weight of each particle being in the range of from about 78:22 to about 90:10.
Claim 21
Dependent Claim
50 words
An abradable seal assembly according to claim 18 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the ratio of metallic material to non-metallic material by weight of each particle being in the range of from about 80:20 to about 82:18.
Claim 22
Dependent Claim
32 words
An abradable seal assembly according to claim 16 wherein said abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the metallic material being nickel-chromium-aluminum alloy.
Claim 23
Dependent Claim
52 words
An abradable seal assembly according to claim 20 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the metallic material being nickel-chromium-aluminum alloy containing from about 4 to about 8% by weight chromium and from about 2 to about 6% by weight aluminum.
Claim 24
Dependent Claim
52 words
An abradable seal assembly according to claim 21 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the metallic material being nickel-chromium-aluminum alloy containing from about 4.5 to about 6% by weight chromium and from about 3 to about 5% by weight aluminum.
Claim 25
Dependent Claim
41 words
An abradable seal assembly according to claim 22 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the metallic material being nickel-chromium-aluminum alloy also containing up to about 1% by weight silicon.
Claim 26
Dependent Claim
41 words
An abradable seal assembly according to claim 22 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the metallic material being nickel-chromium-aluminum alloy also containing up to about 1% by weight iron.
Claim 27
Dependent Claim
33 words
An abradable seal assembly according to claim 16 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the non-metallic core material being heat-insulating material.
Claim 28
Dependent Claim
33 words
An abradable seal assembly according to claim 25 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the non-metallic core material being ceramic material.
Claim 29
Dependent Claim
32 words
An abradable seal assembly according to claim 26 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the non-metallic core material being bentonite.
Claim 30
Dependent Claim
32 words
An abradable seal assembly according to claim 26 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder with the non-metallic core material being rhyolite.
Claim 31
Dependent Claim
34 words
An abradable seal assembly according to claim 16 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder wherein each core consists of a single core particle.
Claim 32
Dependent Claim
43 words
An abradable seal assembly according to claim 16 wherein the abradable seal coating has been deposited on the substrate by thermal spraying a composite powder wherein less than about 5% by weight of the particles have a size less than about 45 microns.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-09-21 | 1985-03-23 | 1985-09-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-09-21 | 1989-03-23 | 1989-09-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-09-21 | 1993-03-23 | 1993-09-22 | $7700.00 | Window Closed / Lapsed |