Diffusion coating through restrictions

Claim 2

In the diffusion coating of the internal surface of a hollow in a metal workpiece where that hollow is accessible only through a passageway less than about 5 millimeters wide, the improvement according to which there is applied over that internal surface an essentially uniform layer of particles consisting essentially of all the metal to be diffused into that surface, and the workpiece so treated is subjected to diffusion coating temperature while the hollow is exposed through the passageway to an energizer-containing diffusion coating atmosphere.

Claim 3

The combination of claim 1 in which the passageway is less than 2 millimeters wide.

Claim 4

The combination of claim 1 in which the layer of particles is a layer of a dispersion of the particles in a binder that is driven off at diffusion coating temperature.

Claim 5

The combination of claim 1 in which the essentially uniform layer is applied by first applying a coating of a mobile dispersion of the metal particles in a solution of an organic binder in a liquid solvent and then expelling coating to leave the desired essentially uniform layer.

Claim 6

The combination of claim 4 in which the binder is an acrylic resin.

Claim 7

The combination of claim 4 in which the expelling is accomplished by propelling a stream of gas against the mobile coating so that it moves thickened portions of the coating out the passageway.

Claim 8

The combination of claim 4 in which the expelling is accomplished by applying suction to the passageway to suck out thickened portions of the coating.

Claim 9

The combination of claim 1 in which the diffusion coating atmosphere is that produced by an energizer in contact with the diffusing metal at diffusion coating temperature.

Claim 10

The combination of claim 1 in which the workpiece is a superalloy.

Claim 11

The combination of claim 9 in which the diffusing metal is aluminum or chromium or mixtures of the two containing more than twice as much aluminum as chromium, by weight.

Claim 12

The combination of claim 9 in which the superalloy is a nickel base superalloy.

Claim 13

The combination of claim 1 in which the workpiece is a jet engine blade and the hollow is a cooling passageway in the interior of the blade.

Claim 14

The combination of claim 1 in which the workpiece has its external surface covered with a diffusion-applying layer during the diffusion coating.

Claim 15

The combination of claim 13 in which the diffusion coating applies to both the internal and the external surfaces of the workpiece, diffusion cases of the inward type.

Claim 16

The combination of claim 1 in which the exposure of the internally coated hollow workpiece to an energizer-containing diffusion coating atmosphere is effected by suspending the workpiece in a space contained in a diffusion-coating retort and supplying said atmosphere to that space.

Claim 17

The combination of claim 1 in which the exposure of the internally coated hollow workpiece to an energizer-containing diffusion coating atmosphere is effected by embedding the internally coated hollow workpiece in an activated diffusion-coating pack held in a diffusion-coating retort, and then heating the retort so loaded to diffusion coating temperature.

Claim 18

In the diffusion coating of a workpiece by holding it in a gaseous diffusion coating atmosphere at a diffusion coating temperature until the desired coating is formed on its surface, the improvement according to which the workpiece has an interior accessible only through a passageway less than about 5 millimeters wide, and before the diffusion coating treatment that interior is packed with a dry powdered diffusion coating pack that causes the interior to be diffusion coated by that pack while the exterior of the workpiece is diffusion coated by the diffusion coating atmosphere.

Claim 19

In the diffusion coating of a workpiece by holding it in a gaseous diffusion coating atmosphere at a diffusion coating temperature until the desired coating is formed on its surface, the improvement according to which the workpiece has an interior accessible only through a passageway less than about 5 millimeters wide, and before the diffusion coating treatment that interior is packed with a dry powdered diffusion coating pack that causes the interior to be diffusion coated by that pack while the exterior of the workpiece is diffusion coated by the diffusion coating atmosphere.

Claim 20

The combination of claim 9 in which the layer of particles is applied by introducing into the passageway a dispersion of the particles in a liquid, and before such introduction treating the surface of that passageway with nitric acid having a concentration between about 5 and about 20% by weight and containing up to about 10% fluoride ion by weight, to render that surface better wettable by the dispersion.