Forming a ceramic matrix composite having a silicide layer

Patent metadata

Field	Value
Publication number	US-10233126-B2
Application number	US-201615229786-A
Country	US
Kind code	B2
Filing date	Aug 5, 2016
Priority date	Aug 12, 2015
Publication date	Mar 19, 2019
Grant date	Mar 19, 2019

Abstract

A ceramic matrix composite component and methods of making are described herein. The ceramic matrix composite may include a silicon containing matrix and refractory fibers embedded within the silicon containing matrix. The ceramic matrix composite component may further include a silicide layer sandwiched between the silicon containing matrix and the refractory fibers. A method of forming a ceramic matrix composite may include infiltrating a fluid that includes a refractory metal element containing compound into a fiber preform that includes fibers. The method may further include depositing the refractory metal element from the refractory metal element containing compound onto the fibers and forming, from the refractory metal element deposited onto the fibers, a refractory metal silicide.

First claim

What is claimed is:

1. A method of forming a ceramic matrix composite comprising:
prior to infiltrating a fiber preform comprising fibers with a slurry, infiltrating a fluid comprising a refractory metal element containing compound into the fiber preform comprising fibers;
depositing the refractory metal element from the refractory metal element containing compound onto the fibers;
forming, from the refractory metal element deposited onto the fibers, a refractory metal silicide by at least exposing the refractory metal element to a silicon vapor; and
infiltrating the fiber preform with the slurry.

2. The method of claim 1 , wherein the refractory metal element comprises molybdenum, tungsten, tantalum or a combination thereof.

3. The method of claim 1 , wherein the refractory metal element containing compound comprises molybdenum chloride.

4. The method of claim 1 , wherein the depositing the refractory metal element comprises forming a refractory metal layer comprising the refractory metal element on the fibers, and wherein the forming the refractory metal silicide comprises forming a refractory metal silicide-containing layer on the fibers.

5. The method of claim 4 , wherein the slurry comprises silicon carbide.

6. The method of claim 5 , further comprising melt infiltrating the fiber preform with a molten silicon containing metal or alloy after infiltrating the fiber preform with the slurry.

7. The method of claim 6 , wherein the refractory metal silicide-containing layer substantially restricts chemical diffusion between the fibers and a silicon containing matrix formed as a result of the melt infiltrating.

8. The method of claim 1 , further comprising:
wherein infiltrating the fiber preform with the slurry comprises infiltrating the fiber preform with a slurry comprising silicon carbide; and
melt infiltrating the fiber preform with a molten silicon containing metal or alloy,
wherein silicon from the silicon containing metal or alloy and the refractory metal element form at least a portion of the refractory metal silicide.

9. The method of claim 1 , further comprising forming a refractory metal carbide from the refractory metal element deposited from the refractory metal containing compound prior to forming the refractory metal silicide.

10. The method of claim 9 , further comprising melt infiltrating the fiber preform with a molten silicon containing metal or alloy to convert the refractory metal carbide to the refractory metal silicide.

11. A method of forming a ceramic matrix composite, the method comprising:
prior to infiltrating a fiber preform comprising fibers with a slurry, infiltrating a fluid comprising a refractory metal element containing compound into the fiber preform;
depositing the refractory metal element from the refractory metal element containing compound onto the fibers;
forming, from the refractory metal element deposited onto the fibers, a refractory metal silicide by at least exposing the refractory metal element to a silicon vapor;
infiltrating the fiber preform with a slurry; and
melt infiltrating the fiber preform with a molten silicon containing metal or alloy.

12. The method of claim 11 , wherein the slurry comprises silicon carbide.

Assignees

• Rolls Royce High Temperature Composites Inc
• Rolls Royce Corp

Inventors

• Harris Stephen I
• Shinavski Robert J
• Shim Sungbo
• Landwehr Sean E

Classifications

• C04B2237/122

  based on refractory metals · CPC title

• C23C16/045

  Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates · CPC title

• C04B2237/38

  Fiber or whisker reinforced · CPC title

• C04B37/005

  consisting of glass or ceramic material · CPC title

• C04B35/62894

  with more than one coating layer · CPC title