High temperature oxidation protection for composites

Patent metadata

Field	Value
Publication number	US-10377675-B2
Application number	US-201615169257-A
Country	US
Kind code	B2
Filing date	May 31, 2016
Priority date	May 31, 2016
Publication date	Aug 13, 2019
Grant date	Aug 13, 2019

Abstract

The present disclosure provides a method for coating a composite structure, comprising forming a first slurry by combining a first pre-slurry composition with a first carrier fluid, applying the first slurry on a surface of the composite structure, and heating the composite structure to a temperature sufficient to form a base layer on the composite structure. The first pre-slurry composition may comprise a first phosphate glass composition and a low coefficient of thermal expansion material, wherein the low coefficient of thermal expansion material is a material with a coefficient of thermal expansion of less than 10×10 −6 ° C. −1 .

First claim

What is claimed is:

1. A method for coating a composite structure, comprising:
forming a first slurry by combining a first pre-slurry composition with a first carrier fluid, wherein the first pre-slurry composition comprises a first phosphate glass composition and a low coefficient of thermal expansion material, wherein the low coefficient of thermal expansion material is a material comprising beta-spodumene with a coefficient of thermal expansion of less than 10×10 −6 ° C. −1 ;
applying the first slurry on a surface of the composite structure; and
heating the composite structure to a temperature sufficient to form a base layer on the composite structure.

2. The method of claim 1 , further comprising forming a second slurry by combining a second pre-slurry composition with a second carrier fluid, wherein the second pre-slurry composition comprises a second phosphate glass composition;
applying the second slurry to the base layer; and
heating the composite structure to a second temperature sufficient to form a sealing layer on the base layer.

3. The method of claim 2 , wherein at least one of the first phosphate glass composition or the second phosphate glass composition is represented by the formula a(A′ 2 O) x (P 2 O 5 ) y1 b(G f O) y2C (A″O) z :
A′ is selected from: lithium, sodium, potassium, rubidium, cesium, and mixtures thereof;
G f is selected from: boron, silicon, sulfur, germanium, arsenic, antimony, and mixtures thereof;
A″ is selected from: vanadium, aluminum, tin, titanium, chromium, manganese, iron, cobalt, nickel, copper, mercury, zinc, thulium, lead, zirconium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, actinium, thorium, uranium, yttrium, gallium, magnesium, calcium, strontium, barium, tin, bismuth, cadmium, and mixtures thereof;
a is a number in the range from 1 to about 5;
b is a number in the range from 0 to about 10;
c is a number in the range from 0 to about 30;
x is a number in the range from about 0.050 to about 0.500;
y 1 is a number in the range from about 0.100 to about 0.950;
y 2 is a number in the range from 0 to about 0.20; and
z is a number in the range from about 0.01 to about 0.5;
(x+y 1 +y 2 +z)=1; and
x<(y 1 +y 2 ).

4. The method of claim 2 , wherein at least one of the first slurry or the second slurry comprises at least one of a surfactant, a flow modifier, a polymer, ammonium hydroxide, ammonium dihydrogen phosphate, acid aluminum phosphate, nanoplatelets, or graphene nanoplatelets.

5. The method of claim 1 , further comprising applying at least one of a pretreating composition or a barrier coating to the composite structure prior to applying the first slurry to the composite structure.

6. The method of claim 5 , wherein the barrier coating comprises at least one of a carbide, a nitride, a boron nitride, a silicon carbide, a titanium carbide, a boron carbide, a silicon oxycarbide, a molybdenum disulfide, a tungsten disulfide, or a silicon nitride.

7. The method of claim 1 , further comprising applying a pretreating composition, wherein the applying comprises:
applying a first pretreating composition to an outer surface of the composite structure, the first pretreating composition comprising aluminum oxide and water;
heating the pretreating composition; and
applying a second pretreating composition comprising at least one of a phosphoric acid or an acid phosphate salt, and an aluminum salt on the first pretreating composition, wherein the composite structure is porous and the second pretreating composition penetrates at least a pore of the composite structure.

8. The method of claim 1 , further comprising applying a barrier coating by at least one of reacting the composite structure with molten silicon, spraying, chemical vapor deposition (CVD), molten application, or brushing.

9. The method of claim 1 , wherein the first pre-slurry composition of the base layer comprises between about 15 weight percent and about 30 weight percent of boron nitride.

10. The method of claim 1 , wherein the first slurry comprises a refractory compound such as a nitride, a boron nitride, a silicon carbide, a titanium carbide, a boron carbide, a silicon oxycarbide, silicon nitride, molybdenum disulfide, or tungsten disulfide.

11. A slurry for coating a composite structure, comprising:
a carrier fluid; and
a first pre-slurry composition comprising a first phosphate glass composition and a low coefficient of thermal expansion material,
wherein the low coefficient of thermal expansion material is a material comprising beta-spodumene with a coefficient of thermal expansion of less than 10×10 −6 ° C. −1 .

12. The slurry of claim 11 , wherein the first pre-slurry composition comprises between about 15 weight percent and 30 weight percent boron nitride.

13. The slurry of claim 11 , wherein the first phosphate glass composition is represented by the formula a(A′ 2 O) x (P 2 O 5 ) y1 b(G f O) y2C (A″O) z :
A′ is selected from: lithium, sodium, potassium, rubidium, cesium, and mixtures thereof;
G f is selected from: boron, silicon, sulfur, germanium, arsenic, antimony, and mixtures thereof;
A″ is selected from: vanadium, aluminum, tin, titanium, chromium, manganese, iron, cobalt, nickel, copper, mercury, zinc, thulium, lead, zirconium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, actinium, thorium, uranium, yttrium, gallium, magnesium, calcium, strontium, barium, tin, bismuth, cadmium, and mixtures thereof;
a is a number in the range from 1 to about 5;
b is a number in the range from 0 to about 10;
c is a number in the range from 0 to about 30;
x is a number in the range from about 0.050 to about 0.500;
y 1 is a number in the range from about 0.100 to about 0.950;
y 2 is a number in the range from 0 to about 0.20; and
z is a number in the range from about 0.01 to about 0.5;
(x+y 1 +y 2 +z)=1; and
x<(y 1 +y 2 ).

14. The slurry of claim 11 , further comprising a refractory compound such as a nitride, a boron nitride, a silicon carbide, a titanium carbide, a boron carbide, a silicon oxycarbide, silicon nitride, molybdenum disulfide, or tungsten disulfide.

15. The slurry of claim 11 , further comprising at least one of a surfactant, a flow modifier, a polymer, ammonium hydroxide, ammonium dihydrogen phosphate, acid aluminum phosphate, nanoplatelets, or graphene nanoplatelets.

16. An article comprising:
a carbon-carbon composite structure; and
an oxidation protection composition including a base layer disposed on an outer surface of the carbon-carbon composite structure,
wherein the base layer comprises a first pre-slurry composition having a low coefficient of thermal expansion material, wherein the low coefficient of thermal expansion material is a material comprising beta-spodumene with a coefficient of thermal expansion of less than 10×10 −6 ° C. −1 .

17. The article of claim 16 , further comprising a sealing layer disposed on an outer surface of the base layer, wherein the sealing layer comprises a second pre-slurry composition comprising a second phosphate glass composition and acid aluminum phosphate.

Assignees

• Goodrich Corp

Inventors

• Mazany Anthony M
• Poteet Steven A

Classifications

• C04B2111/00362

  Friction materials, e.g. used as brake linings, anti-skid materials · CPC title

• C04B41/85 Primary

  with inorganic materials · CPC title

• C04B41/5022

  with vitreous materials (composition of vitreous glazes and enamels C03C; ceramic pigments C09C1/0009) · CPC title

• C04B35/52

  based on carbon, e.g. graphite · CPC title

• C03C2209/00

  Compositions specially applicable for the manufacture of vitreous glazes · CPC title