Formulations for oxidation protection of composite articles

Patent metadata

Field	Value
Publication number	US-10689290-B2
Application number	US-201816116665-A
Country	US
Kind code	B2
Filing date	Aug 29, 2018
Priority date	Mar 27, 2015
Publication date	Jun 23, 2020
Grant date	Jun 23, 2020

Abstract

The present disclosure includes carbon-carbon composite articles having oxidation protection coatings for limiting thermal and catalytic oxidation reactions and methods for applying oxidation protection coatings to carbon-carbon composite articles.

First claim

What is claimed is:

1. A method for limiting an oxidation reaction in a composite substrate, comprising:
applying a base layer comprising a first phosphate glass composition on an outer surface of a carbon-carbon composite structure, wherein the first phosphate glass composition comprises a plurality of graphene nanoplatelets and a boron nitride additive; and
heating the carbon-carbon composite structure to a temperature sufficient to adhere the base layer to the carbon-carbon composite structure.

2. The method of claim 1 , wherein the first phosphate glass composition of the base layer comprises between about 15 weight percent and about 30 weight percent the boron nitride additive.

3. The method of claim 1 , 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) y2 c(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 0.040 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 1 , further comprising:
applying a sealing layer comprising a second phosphate glass composition on an outer surface of the base layer, wherein the second phosphate glass composition is substantially free of boron nitride; and
heating the carbon-carbon composite structure to a temperature sufficient to adhere the sealing layer to the base layer.

5. The method of claim 4 , wherein the second phosphate glass composition is represented by the formula a(A′ 2 O) x (P 2 O 5 ) y1 b(G f O) y2 c(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 0.040 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 ).

6. The method of claim 4 , further comprising forming a second slurry of the second phosphate glass composition by combining the second phosphate glass composition with a second carrier fluid, wherein applying the sealing layer of the second phosphate glass composition on the base layer comprises spraying or brushing the second slurry of the second phosphate glass composition on the base layer.

7. The method of claim 6 , wherein the second slurry further comprises an aluminum phosphate.

8. The method of claim 1 , comprising forming a first slurry of the first phosphate glass composition by combining a pulverized first phosphate glass matrix with a first carrier fluid, the plurality of graphene nanoplatelets, and the boron nitride additive.

9. The method of claim 1 , wherein prior to applying the base layer of the first phosphate glass composition to the carbon-carbon composite structure, a pretreating composition is applied to the outer surface of the carbon-carbon composite structure, the pretreating composition comprising one of a phosphoric acid and an acid phosphate salt, an one aluminum salt, and an additional salt, and wherein the carbon-carbon composite structure is porous and the pretreating composition penetrates at least some of a plurality of pores of the carbon-carbon composite structure.

10. The method of claim 1 , wherein prior to applying the base layer of the first phosphate glass composition to the carbon-carbon composite structure, a first pretreating composition is applied to the outer surface of the carbon-carbon composite structure, the first pretreating composition comprising aluminum oxide and water, wherein after heating the pretreating composition, a second pretreating composition comprising one of a phosphoric acid and an acid phosphate salt, and an aluminum salt is applied to an outer surface of the first pretreating composition, wherein the carbon-carbon composite structure is porous and the second pretreating composition penetrates at least some of a plurality of pores of the carbon-carbon composite structure.

Assignees

• Goodrich Corp

Inventors

• Mazany Anthony M

Classifications

• C04B41/89 Primary

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

• C03C8/24

  Fusion seal compositions being frit compositions having non-frit additions, i.e. for use as seals between dissimilar materials, e.g. glass and metal; Glass solders · CPC title

• F16D69/023

  Composite materials containing carbon and carbon fibres or fibres made of carbonizable material · CPC title

• C04B41/52

  Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation} · CPC title

• C03C3/064

  containing boron · CPC title