Office Action 1: Notice of Allowance (2025-07-14)

CLAIMS:
CLAIMS

What is claimed is:

1\. A method for coating a metallic substrate, the method comprising:applying a first MCrAIY coating;
machining to remove said first MCrAIY coating from one or more regions of the substrate;
applying a mask having at least a chromium-containing chromizing portion to a combinationof:regions of the substrate from which the first MCrAIY has been removed; and regions of the substrate on which the first MCrA\[Y remains but not on other regions of the substrate on whichthe first MCrAIY remains;
aluminizing:an interior surface region of the substrate; and
at least a portion of the region where the first MCrAIY remains absent the mask,wherein, during the aluminizing, the mask masks from the aluminzing but chromizes the regions to which the chromizing portion was applied; and
removing the mask.

2\. The method of claim 1wherein:the mask is pre-formed and is applied as at least two pieces.

3\. The method of claim 1 wherein the mask comprises:a sintered substrate; and
a chromium halide coating forming the chromizing portion on the sintered substrate.

4\. The method of claim 3 wherein:the sintered substrate comprises alumina, Ni, Cr, and additional Al.

5\. Themethod of claim 4 wherein:the sintered substrate comprises NiAl, NiCr and alumina; and/or the sintered substrate comprises NiAlCr and alumina.

6\. The method of claim 1 wherein:the aluminizing comprises exposing to an aluminum halide activator.

7\. Themethod of claim 1wherein:the first MCrAIY comprises 25% to 40% by weight Cr.

8\. The method of claim 1 wherein:the first MCrAIY comprises 5% to 15% by weight Al.

9\. The method of claim 1wherein the first MCrAIY comprises by weight:25% to 40% Cr;
5% to 15% by weight Al;
0.01%to 2.0% Y;
up to 30% Co;
0.01% to 5.0% Si;
0.01% to 2.0% Hf;
0.01% to 0.10% Zr; and
balance Ni plus impurities.

10\. The method of claim 1wherein the substrate is a blade precursor substrate having:a root section;
an airfoil section; and
a platform section between the root section and the airfoil section, wherein the mask is applied to the root.

11\. The method of claim 10 wherein:the regions of the substrate from which the first MCrAIY has been removed by the machining but to which the chromizing portion was applied comprise surfaces of the root section;
the regions of the substrate on which the first MCrAIY has not been removed by the machining but to which the chromizing portion was applied comprise an underside of the platform section; and
the other regions of the substrate on which the first MCrAIY has not been removed by the machining comprise a majority of a lateral surface of the airfoil section and an outer diameter surface of the platform section.SVG {EMBED HERE} 0.1170.15

12\. The method of claim 11wherein one of:a tip of the airfoil is a region of the substrate from which the first MCrAIYhas been removed by the machining but to which the mask was not applied; and
said other regions of the substrate on which the first MCrAIY has not been removed by the machining but to which the chromizing portion was not applied comprise a tip of the airfoil section.
13\. The method of claim SVG {EMBED HERE} 0.1130.03711 wherein:
a region of the substrate from which the first MCrAIY has been removed but to whichaportion of the maskother than the chromizing portion was applied comprises an inner diameter face of the root.

14\. The method of claim 1 further comprising:applying a ceramic coating along at least some of said other regions of the substrate on which the first MCrAIY remains.

15\. A blade having a metallic substrate with internal passageways and having:an attachment root having one or more inlets to the passageways;
an airfoil through which the passageways pass;
a platform between the root and the airfoil and having an underside surface adjacent the root and a gaspath surface adjacent the airfoil;
a first coating along a majority of the airfoil comprising:one or more NiCoCrAIY layers progressively outwardly increasing in aluminum content; and
one ormore ceramic layers;
a second coating along the internal passageways comprising:an aluminization;
a third coating along the root comprising:a NiCoCr chromization; and
a fourth coating (30) along the underside of the platform comprising:a NiCoCrAIY layer; and
a NiCoCrAIY plus alpha-Cr layer.

16\. The blade of claim 15wherein the blade further comprises:SVG {EMBED HERE} 0.1170.15a fifth coating on a tip of the airfoil comprising:
a NiCoCrAIYlayer; and
an abrasive layer.

17\. The blade of claim 15 wherein:the first coating further comprises an alumina TGO;
the second coating further comprises an alumina TGO;
the third coating further comprises a chromia TGO; and
the fourthcoating further comprises a chromia TGO.

18\. The blade of claim 15wherein:the first coating progressive aluminum increase is at least a difference of 5.0% by weight;
the fourth coating NiCoCrAIY plus alpha-Cr layer has at least 70% Cr by weight;
the blade has a Ni-alloy substrate; and;
the root is a firtree root.

19\. A method for coating a metallic substrate, the method comprising:applying a first MCrAIY coating;
machining the substrate after application of the first MCrAIY coating to remove said first MCrAIY coating from one or more regions of the substrate; and
a step for simultaneously:
aluminizing:
an interior surface region of the substrate lacking the first MCrAIY; and
at least a portion of a region where the first MCrAIY remains; and
chromizing:an exterior surface region of the substrate lacking the first MCrAIY; and at least a different portion of the region where the first MCrAIY remains.

20\. Themethod of claim 19 wherein:said exterior surface region of the substrate lacking the first MCrAIY includes at least a portion of the one or more regions of the substrate from which the first MCrAIY was removed.

OFFICE ACTION:
DETAILED ACTION
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
This action is in response to the claims filed 12/18/2024.
Claims 1-20 are presented for examination.
Information Disclosure Statement
The information disclosure statements (IDS) submitted on 1/3/2025 and 6/17/2025 are in compliance with the provisions of 37 CFR 1.97.  Accordingly, the information disclosure statement is being considered by the examiner.
Allowable Subject Matter
Claims 1-20 allowed.
The following is an examiner’s statement of reasons for allowance.  The prior art of record, either alone or in combination, is silent to each and every limitation required of the claims.
The prior art of record demonstrates various analogous coated substrates, including coated blades, and methods of coating including aluminizing, chromizing, and employing masking to selectively coat particular regions of substrates.  However, the prior art does not disclose or suggest in combination the particularly laid forth coating methods of claim 1 or 19 or the specific coated hollow blade structure of claim 15.
US20240344192 to Freedman et al. discloses (claims 1-20; par. 54-68) (i) a mask comprising at least two sintered pieces comprising a NiAlCr composition (claims 1-7) and (ii) a method of aluminizing involving the use of the aforementioned mask (claims 16-18). The above mask of Freedman corresponds to the mask of the instantly claimed invention. Nevertheless, the method of Freedman comprises the steps of firstly applying a mask on the surface of a component, then aluminizing the interior of the component, then removing the mask and finally applying a MCrAlY coating.  However, the method of the application comprises a first step of applying a MCrAlY coating, then machining, then applying a mask and then aluminizing the interior of the component.
US4617202 discloses a method of coating a blade including chromizing combined with masked aluminizing (see example 2 in column 6), but not the method or coated product specifically claimed in the instant invention.
US10113225 discloses a mask used in aluminizing of superalloy turbine component, such as a turbine blade, where a region exposed to relatively high operating temperature is aluminized to form a diffusion aluminide coating and another region exposed to relatively lower operating temperatures is masked to prevent aluminizing of the masked region while concurrently being enriched in Cr and/or retaining a pre-existing Cr-content from the superalloy chemistry itself or from a previous chromizing operation.
US11719105 discloses a method of coating a component including aluminizing an array of internal passageways within the component; and chromizing a portion of the array of internal passageways within the component, and a component, including an airfoil having an array of aluminized internal passageways, the array of aluminized internal passageways chromized up to a demarcation.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion



CITED REFERENCE SUMMARIES: Ref US20240344192A1: Claims:
A masking apparatus for masking a part during coating and comprising at least two sintered pieces of a mask material wherein: the at least two sintered pieces have an assembled condition forming a compartment shaped to accommodate an airfoil of the part; and the at least two sintered pieces have an average overall composition of: nickel as a largest by-weight constituent; aluminum as a second largest by-weight constituent; and chromium as a third largest by-weight constituent.
the at least two sintered pieces have an assembled condition forming a compartment shaped to accommodate an airfoil of the part; and
the at least two sintered pieces have an average overall composition of: nickel as a largest by-weight constituent; aluminum as a second largest by-weight constituent; and chromium as a third largest by-weight constituent.
nickel as a largest by-weight constituent;
aluminum as a second largest by-weight constituent; and
chromium as a third largest by-weight constituent.
The masking apparatus of claim 1 wherein the average overall composition by weight has: at least 82.0% nickel; at least 8.0% aluminum; and at least 0.5% chromium.
at least 82.0% nickel;
at least 8.0% aluminum; and
at least 0.5% chromium.
The masking apparatus of claim 1 wherein the average overall composition by weight has: no more than 5.0% elements other than said nickel, aluminum, and chromium.
no more than 5.0% elements other than said nickel, aluminum, and chromium.
The masking apparatus of claim 1 wherein the average overall composition by weight has: 82.0% to 91.0% nickel; 8.0% to 17.0% aluminum; and 0.5% to 4.0% chromium.
0% to 91.0% nickel;
0% to 17.0% aluminum; and
5% to 4.0% chromium.
The masking apparatus of claim 1 wherein: the powder comprises at least 70% a NiAlCr alloy powder and 20% a blend of NiAl powder and elemental nickel powder.
the powder comprises at least 70% a NiAlCr alloy powder and 20% a blend of NiAl powder and elemental nickel powder.
The masking apparatus of claim 1 wherein the at least two sintered pieces comprise: a first piece; and a second piece, wherein in the assembled condition: the first piece and second piece form a first compartment shaped to enclose an airfoil of the part.
a first piece; and
wherein in the assembled condition:
the first piece and second piece form a first compartment shaped to enclose an airfoil of the part.
The masking apparatus of claim 6 wherein the at least two sintered pieces further comprise: a third piece; and a fourth piece, wherein in the assembled condition: the third piece and the fourth piece form a second compartment shaped to accommodate a firtree root or root precursor of the part.
a third piece; and
the third piece and the fourth piece form a second compartment shaped to accommodate a firtree root or root precursor of the part.
A coating apparatus including the apparatus of claim 1 and further comprising: a gas manifold having spigot portions for mating with inlet ports of the part.
a gas manifold having spigot portions for mating with inlet ports of the part.
The coating apparatus of claim 8 wherein: the inlet ports are in a blade root or blade root precursor of the part; and the spigot portions are received in the inlet ports.
the inlet ports are in a blade root or blade root precursor of the part; and
the spigot portions are received in the inlet ports.
A method for manufacturing the masking apparatus of claim 1 , the method comprising: forming the at least two sintered pieces by sintering a blend of metallic powders and a binder.
forming the at least two sintered pieces by sintering a blend of metallic powders and a binder.
The method of claim 10 wherein: the blend comprises NiCrAl powder, NiAl powder, and Ni powder.
the blend comprises NiCrAl powder, NiAl powder, and Ni powder.
A method for using the masking apparatus of claim 1 , the method comprising: assembling the at least two sintered pieces to the assembled condition over a turbine engine airfoil element, so that the compartment accommodates an airfoil of the airfoil element; and flowing an aluminization vapor through the airfoil element.
assembling the at least two sintered pieces to the assembled condition over a turbine engine airfoil element, so that the compartment accommodates an airfoil of the airfoil element; and
flowing an aluminization vapor through the airfoil element.
The method of claim 12 further comprising: applying a collar around the at least two sintered pieces.
applying a collar around the at least two sintered pieces.
The method of claim 12 wherein: the at least two sintered pieces further comprise: a third piece; and a fourth piece, wherein in the assembled condition the third piece and the fourth piece form a second compartment shaped to accommodate a firtree root of the part; and the method further comprises: mating a manifold to the firtree root, the mating comprising inserting spigots of the manifold into inlet ports of the firtree root; assembling the third piece and fourth piece to the firtree root; and inserting the assembled third piece and fourth piece to a body of a fixture, the inserting mating an inlet of the manifold to an inlet conduit of the fixture.
the at least two sintered pieces further comprise: a third piece; and a fourth piece, wherein in the assembled condition the third piece and the fourth piece form a second compartment shaped to accommodate a firtree root of the part; and
a fourth piece, wherein in the assembled condition the third piece and the fourth piece form a second compartment shaped to accommodate a firtree root of the part; and
the method further comprises: mating a manifold to the firtree root, the mating comprising inserting spigots of the manifold into inlet ports of the firtree root; assembling the third piece and fourth piece to the firtree root; and inserting the assembled third piece and fourth piece to a body of a fixture, the inserting mating an inlet of the manifold to an inlet conduit of the fixture.
mating a manifold to the firtree root, the mating comprising inserting spigots of the manifold into inlet ports of the firtree root;
assembling the third piece and fourth piece to the firtree root; and
inserting the assembled third piece and fourth piece to a body of a fixture, the inserting mating an inlet of the manifold to an inlet conduit of the fixture.
The method of claim 12 further comprising: removing the at least two sintered pieces; and applying a metallic coating to an exterior surface of the part.
removing the at least two sintered pieces; and
applying a metallic coating to an exterior surface of the part.
A method for manufacturing a cooled part, the method comprising: applying a pre-formed mask to a cast substrate having an exterior surface and an interior surface; aluminizing the interior surface; removing the pre-formed mask; and applying a metallic coating to the exterior surface, wherein: the mask comprises a sintered body of a mask material; the mask material comprises nickel and aluminum.
applying a pre-formed mask to a cast substrate having an exterior surface and an interior surface;
aluminizing the interior surface;
removing the pre-formed mask; and
applying a metallic coating to the exterior surface,
the mask comprises a sintered body of a mask material;
the mask material comprises nickel and aluminum.
The method of claim 16 wherein: the applying the metallic coating is via cathodic arc deposition.
the applying the metallic coating is via cathodic arc deposition.
The method of claim 16 wherein the metallic coating comprises: MCrAlY.
The method of claim 16 further comprising: forming the mask by compacting and sintering one or more powders.
forming the mask by compacting and sintering one or more powders.
The method of claim 19 wherein the sintered one or more powders have an average overall composition of: nickel as a largest by-weight constituent; aluminum as a second largest by-weight constituent; and chromium as a third largest by-weight constituent.
Ref US4617202A: Claims:
What is claimed: 1. A composition for masking against diffusion coating, the composition consisting essentially of a used diffusion-chromizing pack which before that use contained from about 0.6 to about 2% chromium, a nickel content from about 1/2 to about 3 times the chromium content, and an aluminum content about 1/10 to about 1/3 the chromium content. 2. In the diffusion aluminizing of a portion of the surface of a metal workpiece at a temperature not over 1400° F., while masking the remainder of the surface against such aluminizing, the improvement according to which the masking is an adherent layer of the composition of claim 2. 3. A composition for masking against diffusion coating, the composition consisting essentially of a used single-use diffusion-chromizing pack which before that single use contained refractory diluent mixed with about 1.2% chromium, about 2.4% nickel and about 0.37% aluminum. 4. The composition of claim 2 mixed with sufficient binder and solvent to make an adherent coating mixture. 5. The composition of claim 3 mixed with sufficient binder and solvent to make an adherent coating mixture. 6. A single-use diffusion-chromizing composition consisting essentially of refractory diluent mixed with from about 0.6 to about 2% chromium, nickel in an amount from about 1/2 to about 3 times the chromium content, and aluminum in an amount from about 1/10 to about 1/3 the chromium content.
A composition for masking against diffusion coating, the composition consisting essentially of a used diffusion-chromizing pack which before that use contained from about 0.6 to about 2% chromium, a nickel content from about 1/2 to about 3 times the chromium content, and an aluminum content about 1/10 to about 1/3 the chromium content.
In the diffusion aluminizing of a portion of the surface of a metal workpiece at a temperature not over 1400° F., while masking the remainder of the surface against such aluminizing, the improvement according to which the masking is an adherent layer of the composition of claim 2.
A composition for masking against diffusion coating, the composition consisting essentially of a used single-use diffusion-chromizing pack which before that single use contained refractory diluent mixed with about 1.2% chromium, about 2.4% nickel and about 0.37% aluminum.
The composition of claim 2 mixed with sufficient binder and solvent to make an adherent coating mixture.
The composition of claim 3 mixed with sufficient binder and solvent to make an adherent coating mixture.
A single-use diffusion-chromizing composition consisting essentially of refractory diluent mixed with from about 0.6 to about 2% chromium, nickel in an amount from about 1/2 to about 3 times the chromium content, and aluminum in an amount from about 1/10 to about 1/3 the chromium content.
Ref US10113225B2: [content unavailable]
Ref US11719105B2: [content unavailable]
Ref US20240344192: Claims:
1. A masking apparatus for masking a part during coating and comprising at least two sintered pieces of a mask material wherein:
the at least two sintered pieces have an assembled condition forming a compartment shaped to accommodate an airfoil of the part; and the at least two sintered pieces have an average overall composition of:
nickel as a largest by-weight constituent;
aluminum as a second largest by-weight constituent; and
chromium as a third largest by-weight constituent.
2. The masking apparatus of claim 1 wherein the average overall composition by weight has:
at least 82.0% nickel;
at least 8.0% aluminum; and
at least 0.5% chromium.
3. The masking apparatus of claim 1 wherein the average overall composition by weight has:
no more than 5.0% elements other than said nickel, aluminum, and chromium.
4. The masking apparatus of claim 1 wherein the average overall composition by weight has:
82.0% to 91.0% nickel;
8.0% to 17.0% aluminum; and
0.5% to 4.0% chromium.
5. The masking apparatus of claim 1 wherein:
the powder comprises at least 70% a NiAlCr alloy powder and 20% a blend of NiAl powder and elemental nickel powder.
6. The masking apparatus of claim 1 wherein the at least two sintered pieces comprise:
a first piece; and
a second piece,
wherein in the assembled condition:
the first piece and second piece form a first compartment shaped to enclose an airfoil of the part.
7. The masking apparatus of claim 6 wherein the at least two sintered pieces further comprise:
a third piece; and
a fourth piece,
wherein in the assembled condition:
the third piece and the fourth piece form a second compartment shaped to accommodate a firtree root or root precursor of the part.
8. A coating apparatus including the apparatus of claim 1 and further comprising:
a gas manifold having spigot portions for mating with inlet ports of the part.
9. The coating apparatus of claim 8 wherein:
the inlet ports are in a blade root or blade root precursor of the part; and
the spigot portions are received in the inlet ports.
10. A method for manufacturing the masking apparatus of claim 1, the method comprising:
forming the at least two sintered pieces by sintering a blend of metallic powders and a binder.
11. The method of claim 10 wherein:
the blend comprises NiCrAl powder, NiAl powder, and Ni powder.
12. A method for using the masking apparatus of claim 1, the method comprising:
assembling the at least two sintered pieces to the assembled condition over a turbine engine airfoil element, so that the compartment accommodates an airfoil of the airfoil element; and flowing an aluminization vapor through the airfoil element.
13. The method of claim 12 further comprising:
applying a collar around the at least two sintered pieces.
14. The method of claim 12 wherein:
the at least two sintered pieces further comprise:
a third piece; and
a fourth piece, wherein in the assembled condition the third piece and the fourth piece form a second compartment shaped to accommodate a firtree root of the part; and

the method further comprises:
mating a manifold to the firtree root, the mating comprising inserting spigots of the manifold into inlet ports of the firtree root;
assembling the third piece and fourth piece to the firtree root; and
inserting the assembled third piece and fourth piece to a body of a fixture, the inserting mating an inlet of the manifold to an inlet conduit of the fixture.
15. The method of claim 12 further comprising:
removing the at least two sintered pieces; and
applying a metallic coating to an exterior surface of the part.
16. A method for manufacturing a cooled part, the method comprising:
applying a pre-formed mask to a cast substrate having an exterior surface and an interior surface; aluminizing the interior surface; removing the pre-formed mask; and applying a metallic coating to the exterior surface, wherein: the mask comprises a sintered body of a mask material; the mask material comprises nickel and aluminum.
17. The method of claim 16 wherein:
the applying the metallic coating is via cathodic arc deposition.
18. The method of claim 16 wherein the metallic coating comprises:
MCrAlY.
19. The method of claim 16 further comprising:
forming the mask by compacting and sintering one or more powders.
20. The method of claim 19 wherein the sintered one or more powders have an average overall composition of:
nickel as a largest by-weight constituent;
aluminum as a second largest by-weight constituent; and
chromium as a third largest by-weight constituent.
Ref US10113225D: [content unavailable]
Ref US11719105D: [content unavailable]