US 12,404,867 B2
Wheels having a bi-layered coating including a hard coating layer and methods for making the same
Philippe Renaud, Sanchey (FR); and Palaniappa Murukesan, Bangalore (IN)
Assigned to Garrett Transportation I Inc., Torrance, CA (US)
Filed by Garrett Transportation I Inc., Torrance, CA (US)
Filed on Jun. 12, 2023, as Appl. No. 18/333,129.
Claims priority of application No. 202311016220 (IN), filed on Mar. 10, 2023.
Prior Publication US 2024/0301887 A1, Sep. 12, 2024
Int. Cl. F04D 29/02 (2006.01)
CPC F04D 29/023 (2013.01) [F05D 2230/31 (2013.01); F05D 2230/90 (2013.01); F05D 2300/611 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A wheel comprising:
a hub portion configured to rotate about a rotational axis; and
a plurality of blades extending radially outward from the hub portion, wherein each blade of the plurality of blades comprises a leading edge and a trailing edge,
wherein the hub portion and the plurality of blades comprise a substrate metal that comprises aluminum or an alloy thereof,
wherein the substrate metal of the plurality of blades has coated directly thereon a first coating layer comprising electroless nickel-phosphorous that comprises a phosphorous content of 12 wt. % to 15 wt. %, and wherein the first coating layer is formed by electroless plating and is subsequently heat treated to enhance adhesion to the substrate metal, and
wherein the first coating layer has coated directly thereon a second hard coating layer overlaying the leading edges of the plurality of blades and formed of a physical vapor deposition (PVD)-compatible material, wherein the second hard coating layer has a thickness that is greatest at the leading edges and decreases rearward in a gradually tapering manner such that the thickness is zero microns at or longitudinally forward of the trailing edges of the plurality of blades.