Braze material for ceramic matrix composite articles

Patent metadata

Field	Value
Publication number	US-11110692-B2
Application number	US-201816137897-A
Country	US
Kind code	B2
Filing date	Sep 21, 2018
Priority date	Oct 3, 2017
Publication date	Sep 7, 2021
Grant date	Sep 7, 2021

Abstract

In some examples, a braze material includes a first set of particles, a second set of particles, and a polymeric binder. The first set of particles includes a braze powder, where the braze powder comprises an Si-containing alloy. The first set of particles defines an average or median particle diameter between about 1 μm and about 40 μm. The second set of particles includes at least one of SiC or a transition metal carbide, where the second set of particles has a multimodal particle size distribution.

First claim

What is claimed is:

1. A braze material comprising:
a first set of particles comprising a braze powder, wherein the braze powder comprises an Si-containing alloy, and wherein the first set of particles defines a median particle diameter between about 1 μm and about 40 μm;
a second set of particles comprising at least one of SiC or a transition metal carbide, wherein the second set of particles has a multimodal particle size distribution; and
a polymeric binder.

2. The braze material of claim 1 , wherein the second set of particles has a bimodal particle size distribution.

3. The braze material of claim 1 , wherein the first set of particles defines a median particle diameter between about 25 μm and about 40 μm.

4. The braze material of claim 1 , further comprising an additive comprising at least one of C, Si metal, a silicide, or a carbide.

5. The braze material of claim 1 , wherein the Si-containing alloy comprises at least one of a Si—Ti alloy, a Si—Al—Ti alloy, a Si—Co—V—Ti alloy, or a Si—Ti—Ni—Co—Cr alloy.

6. The braze material of claim 1 , wherein each particle size distribution of the multimodal particle size distribution of the second set of particles defines a median particle size between about 0.3 μm and about 45 μm.

7. The braze material of claim 1 , wherein the braze material comprises between about 40 weight % and about 60 weight % of the first set of particles, between about 40 weight % and about 60 weight % of the second set of particles, and between about 5 weight % and about 20 weight % of the polymeric binder, with a total of 100 weight %.

8. The braze material of claim 1 , wherein the polymeric binder comprises a dispersant.

9. The braze material of claim 1 , wherein the first set of particles and the second set of particles are each substantially evenly distributed throughout the braze material.

10. The braze material of claim 1 , wherein the braze material comprises one of a tape, a slurry, a paste, and a pre-sintered preform.

11. A method of repairing a ceramic matrix composite component comprising:
removing a damaged portion of a ceramic matrix composite component to define a repair surface;
applying a braze material to the repair surface, wherein the braze material comprises:
a first set of particles comprising a braze powder, wherein the braze power comprises a Si-containing alloy, and wherein the first set of particles defines a median particle diameter between about 1 μm and about 40 μm;
a second set of particles comprising at least one of SiC or a transition metal carbide, wherein the second set of particles has a multimodal particle size distribution; and
a polymeric binder; and

heating the ceramic matrix composite component and the braze material to form a repaired article.

12. The method of claim 11 , further comprising, prior to applying the braze material, cleaning the repair surface.

13. The method of claim 11 , wherein the second set of particles has a bimodal particle size distribution.

14. The method of claim 11 , wherein the first set of particles defines a median particle diameter between about 25 μm and about 40 μm.

15. The method of claim 11 , wherein the braze material further comprises an additive comprising at least one of C, Si metal, a silicide, or a carbide.

16. The method of claim 11 , wherein the Si-containing alloy comprises at least one of a Si—Ti alloy, a Si—Al—Ti alloy, a Si—Co—V—Ti alloy, or a Si—Ti—Ni—Co—Cr alloy.

17. The method of claim 11 , wherein each particle size distribution of the multimodal particle size distribution of the second set of particles defines a median particle size between about 0.3 μm and about 45 μm.

18. The braze material of claim 11 , wherein the braze material of the repaired article comprises between about 20 weight % and about 60 weight % of SiC.

19. The method of claim 11 , wherein the first set of particles and the second set of particles are each substantially evenly distributed throughout the braze material.

20. An assembly comprising:
a ceramic matrix composite component defining a repair surface; and
a braze material on the repair surface, wherein the braze material comprises:
a first set of particles comprising a braze powder, wherein the braze powder comprises an Si-containing alloy, and wherein the first set of particles defines a median particle diameter between about 1 μm and about 40 μm;
a second set of particles comprising at least one of SiC or a transition metal carbide, wherein the second set of particles has a multimodal particle size distribution; and
a polymeric binder.

Assignees

• Rolls Royce Corp

Inventors

• Nelson Scott
• Xu Raymond Ruiwen
• Landwehr Sean E
• Vetters Daniel Kent
• Tatar Samantha

Classifications

• F05D2300/2261

  of silicon · CPC title

• B32B27/20 Primary

  using fillers, pigments, thixotroping agents · CPC title

• C08L2666/44

  Silicon-containing compounds · CPC title

• C08K3/34

  Silicon-containing compounds · CPC title

• Y10T428/25

  Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles · CPC title