Reducing impurities in ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-10611697-B2
Application number	US-201615299771-A
Country	US
Kind code	B2
Filing date	Oct 21, 2016
Priority date	Oct 22, 2015
Publication date	Apr 7, 2020
Grant date	Apr 7, 2020

Abstract

Example techniques may include depositing a slurry on at least a predetermined surface region of a ceramic matrix composite substrate. The slurry may include a solvent and particles comprising at least one of silicon metal or silicon carbide. The slurry may be dried to form a wicking layer on the predetermined surface region. The ceramic matrix composite substrate and the wicking layer may be heated to a temperature of at least 900° C. to wick at least one wickable species from the ceramic matrix composite substrate into the wicking layer. Substantially all of the wicking layer may be removed from the predetermined surface region. Example articles may include a ceramic matrix composite substrate. A wicking layer may be disposed on at least a predetermined surface region of the ceramic matrix composite substrate. The wicking layer may include at least one wicked species wicked from the ceramic matrix composite substrate.

First claim

The invention claimed is:

1. A method comprising:
depositing a slurry on at least a predetermined surface region of a ceramic matrix composite substrate, wherein the slurry comprises a solvent and particles comprising at least one of silicon metal or silicon carbide;
drying the slurry to form a wicking layer on the predetermined surface region; heating the ceramic matrix composite substrate and the wicking layer to a temperature of at least 900° C. to wick at least one wickable species from the ceramic matrix composite substrate into the wicking layer, wherein the heating is performed in an atmosphere containing oxygen; and
removing at least a portion of the wicking layer from the predetermined surface region.

2. The method of claim 1 , wherein the particles have average particle sizes ranging between 1 μm and 50 μm.

3. The method of claim 2 , wherein the particles include a first plurality of particles having a first average particle size, and a second plurality of particles having a second average particle size different from the first average particle size.

4. The method of claim 1 , wherein the slurry contains between 10 vol. % and 80 vol. % of the particles, based on the total volume of the slurry.

5. The method of claim 1 , wherein the wicking layer has a thickness between 25 μm to 1000 μm.

6. The method of claim 1 , wherein the atmosphere containing oxygen comprises air.

7. The method of claim 1 , wherein the wickable species comprises at least one of Al, B, Mg, Fe, or Ca.

8. The method of claim 1 , wherein the heating is performed for a time between 1 hour and 10 hours.

9. The method of claim 1 , wherein the temperature is less than 1400° C.

10. The method of claim 1 , wherein heating the ceramic matrix composite substrate and the wicking layer to a temperature of at least 900° C. causes formation of at least one of a silicon glass or a low melting liquid phase by reaction of silicon with the at least one wickable species and transport of the at least one of the silicon glass or the low melting liquid phase from the densified ceramic matrix composite into the wicking layer.

11. The method of claim 1 , wherein the ceramic matrix composite comprises a SiC—SiC matrix composite, and wherein the SiC—SiC matrix composite includes fewer impurities after heating the ceramic matrix composite substrate and the wicking layer to a temperature of at least 900° C. than before the ceramic matrix composite substrate and the wicking layer to a temperature of at least 900° C.

12. The method of claim 1 , wherein the removing the wicking layer comprises grit blasting the wicking layer.

13. The method of claim 1 , further comprising, after removing the at least the portion of the wicking layer, applying an environment barrier coating to at least the predetermined surface region.

14. The method of claim 13 , wherein the environment barrier coating comprises a rare earth silicate.

15. The method of claim 1 , wherein the wickable species comprise boron.

16. The method of claim 1 , wherein removing the at least the portion of the wicking layer from the predetermined surface region comprises removing all of the wicking layer from the predetermined surface region.

17. A method comprising:
depositing a slurry on at least a predetermined surface region of a ceramic matrix composite substrate, wherein the slurry comprises a solvent and particles comprising at least one of silicon metal or silicon carbide;
drying the slurry to form a wicking layer on the predetermined surface region;
heating the ceramic matrix composite substrate and the wicking layer to a temperature of at least 900° C. to wick at least one wickable species from the ceramic matrix composite substrate into the wicking layer, wherein the heating is performed in an atmosphere containing air; and
removing at least a portion of the wicking layer from the predetermined surface region.

Assignees

• Rolls Royce Corp
• Rolls Royce High Temperature Composites Inc

Inventors

• Shim Sungbo
• Lee Kang N

Classifications

• C04B41/009

  characterised by the material treated · CPC title

• C04B41/0072

  Heat treatment · CPC title

• C04B35/80

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• C04B41/89

  for obtaining at least two superposed coatings having different compositions · CPC title

• F05D2300/2102

  Glass · CPC title