Ceramic matrix composite and method and article of manufacture

Patent metadata

Field	Value
Publication number	US-10370301-B2
Application number	US-201414210928-A
Country	US
Kind code	B2
Filing date	Mar 14, 2014
Priority date	Mar 15, 2013
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

A ceramic matrix composite having improved operating characteristics includes a barrier layer.

First claim

What is claimed is:

1. A ceramic matrix composite comprising:
a matrix; and
a fiber preform embedded within the matrix;
wherein the matrix includes a rigidization layer comprising silicon carbide on the fiber preform, an infiltration layer on the rigidization layer, and a barrier layer sandwiched between the rigidization layer and the infiltration layer, the barrier layer comprising silicon nitro-carbide or silicon nitride.

2. The ceramic matrix composite of claim 1 wherein the ceramic matrix composite material has a porosity of less than about 5 volume percent of the total ceramic matrix composite.

3. The ceramic matrix composite of claim 1 wherein the fiber preform comprises silicon carbide or silicon nitro-carbide fibers, and
further comprising a fiber interface coating between the fiber preform and the rigidization layer, the fiber interface coating comprising boron nitride or pyrolytic carbon.

4. The ceramic matrix composite of claim 1 wherein the barrier layer has a thickness of between about 0.1 μm and about 10 μm.

5. The ceramic matrix composite of claim 1 wherein the barrier layer has a thickness of between about 1 μm and about 2 μm.

6. The ceramic matrix composite of claim 1 wherein the barrier layer comprises between about 2 volume percent and about 10 volume percent of the total ceramic matrix composite.

7. The ceramic matrix composite of claim 1 wherein the barrier layer comprises a combination barrier layer including an underlayer comprising the silicon nitro-carbide or silicon nitride and an overlayer comprising pyrolytic carbon.

8. The ceramic matrix composite of claim 1 wherein the barrier layer comprises silicon-nitro-carbide and pyrolytic carbon.

9. The ceramic matrix composite of claim 1 wherein the fiber preform comprises about 15 volume percent to about 45 volume percent of the total ceramic matrix composite; and wherein the rigidization layer comprises between about 15 volume percent and about 40 volume percent of the total ceramic matrix composite.

10. The ceramic matrix composite of claim 1 wherein the preform comprises fiber formed from a compound selected from the group consisting of: silicon-carbide and silicon nitro-carbide; and
wherein the ceramic matrix composite further comprises a fiber interface coating generally encapsulating the fiber, the fiber interface coating comprising between about 0.1 volume percent and about 10 volume percent of the total ceramic matrix composite; and wherein the fiber interface coating is deposited by chemical vapor infiltration and comprises one or more compounds selected from the group consisting of: boron nitride and pyrolytic carbon.

11. The ceramic matrix composite of claim 1
wherein the infiltration layer comprises slurry additives and melt additives;
wherein the slurry additives comprise silicon-carbide particulates and the melt additives comprise silicon; wherein the slurry additives comprise between about 10 volume percent and about 55 volume percent of the total ceramic matrix composite; and
wherein the melt additives comprise between about 5 volume percent and about 20 volume percent of the total ceramic matrix composite;
wherein the rigidization layer comprises a silicon-carbide layer deposited by chemical vapor infiltration;
wherein the barrier layer is deposited by chemical vapor infiltration;
wherein the preform comprises fibers selected from the group consisting of: silicon-carbide fibers, silicon-nitro-carbide fibers, carbon fibers, and oxide ceramic fibers; and
wherein the fibers are selected from the group consisting of: stoichiometric fibers, non-stoichiometric fibers, and a combination of stoichiometric fibers and non-stoichiometric fibers.

12. An article of manufacture made of a ceramic matrix composite comprising
a matrix; and
a fiber preform embedded within the matrix;
wherein the matrix includes a rigidization layer comprising silicon carbide on the fiber preform, an infiltration layer on the rigidization layer, and a barrier layer sandwiched between the rigidization layer and the infiltration layer, the barrier layer comprising silicon nitro-carbide or silicon nitride.

Assignees

• Rolls Royce Corp

Inventors

• Chamberlain Adam L
• Lazur Andrew J
• Shinavski Robert J

Classifications

• Y10T428/249928

  Fiber embedded in a ceramic, glass, or carbon matrix · CPC title

• C04B2235/77

  Density · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B2235/614

  Gas infiltration of green bodies or pre-forms · CPC title

• C04B2235/5248

  Carbon, e.g. graphite · CPC title