Compositionally-graded metal-ceramic structure and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-11255641-B2
Application number	US-202016892366-A
Country	US
Kind code	B2
Filing date	Jun 4, 2020
Priority date	Sep 5, 2017
Publication date	Feb 22, 2022
Grant date	Feb 22, 2022

Abstract

A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.

First claim

What is claimed is:

1. A method for manufacturing a compositionally-graded structure comprising:
assembling a powder layup comprising at least a first powdered material and a second powdered material, said first powdered material comprising a ceramic component and said second powdered material comprising a metallic component, said powder layup comprising:
a first layer comprising a first concentration of said ceramic component, said first concentration of said ceramic component being at least 80 percent by weight;
a second layer comprising a second concentration of said ceramic component and a first concentration of said metallic component; and
a third layer comprising a third concentration of said ceramic component and a second concentration of said metallic component, said second concentration of said metallic component being at least 60 percent by weight;

pressing said powder layup to yield a compact;
heat treating said compact; and
providing an anti-spalling layer adjacent to said compositionally-graded structure, wherein the anti-spalling layer comprises at least one of a polymer and a fiber.

2. The method of claim 1 wherein a metal element is present in said metallic component, and wherein said metal element is also present in said ceramic component.

3. A method for manufacturing a compositionally-graded structure comprising:
assembling a powder layup comprising at least a first powdered material and a second powdered material, said first powdered material comprising a ceramic component and said second powdered material comprising a metallic component, wherein said metallic component comprises a titanium alloy, said powder layup comprising:
a first layer comprising a first concentration of said ceramic component, said first concentration of said ceramic component being at least 80 percent by weight;
a second layer comprising a second concentration of said ceramic component and a first concentration of said metallic component; and
a third layer comprising a third concentration of said ceramic component and a second concentration of said metallic component, said second concentration of said metallic component being at least 60 percent by weight;

pressing said powder layup to yield a compact; and
heat treating said compact.

4. The method of claim 3 wherein said ceramic component comprises titanium diboride.

5. The method of claim 3 wherein said ceramic component comprises titanium boride.

6. The method of claim 3 wherein said ceramic component comprises titanium carbide.

7. The method of claim 1 wherein said assembling said powder layup comprises assembling said powder layup comprising at least five layers.

8. The method of claim 1 wherein said pressing said powder layup comprises pressing at a pressure ranging from about 10 kpsi to about 16 kpsi.

9. The method of claim 1 wherein said pressing said powder layup is performed after each layer of said powder layup is laid down.

10. The method of claim 1 wherein said heat treating comprises hot isostatic pressing.

11. The method of claim 1 wherein said heat treating comprises hot pressing.

12. The method of claim 1 further comprising, after heat treating, subjecting said compact to a post-processing operation.

13. The method of claim 1 wherein the anti-spalling layer comprises high-density polyethylene.

14. A method for manufacturing a compositionally-graded structure comprising:
assembling a powder layup comprising at least a first powdered material and a second powdered material, said first powdered material comprising a ceramic component and said second powdered material comprising a metallic component, said powder layup comprising:
a first layer comprising a first concentration of said ceramic component, said first concentration of said ceramic component being at least 80 percent by weight;
a second layer comprising a second concentration of said ceramic component and a first concentration of said metallic component; and
a third layer comprising a third concentration of said ceramic component and a second concentration of said metallic component, said second concentration of said metallic component being at least 60 percent by weight;

pressing said powder layup to yield a compact; and
heat treating said compact, wherein said heat treating comprises hot pressing.

15. The method of claim 14 wherein said hot pressing comprises hot isostatic pressing.

16. The method of claim 14 wherein a metal element is present in said metallic component, and wherein said metal element is also present in said ceramic component.

17. The method of claim 14 wherein said metallic component comprises a titanium alloy.

18. The method of claim 17 wherein said ceramic component comprises titanium diboride.

19. The method of claim 17 wherein said ceramic component comprises titanium boride.

20. The method of claim 17 wherein said ceramic component comprises titanium carbide.

Assignees

• Boeing Co

Inventors

• Zamorano Senderos Bruno
• Coad Dennis Lynn
• Dobbs James Ross
• Yousefiani Ali

Classifications

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F2301/205

  Titanium, zirconium or hafnium · CPC title

• B22F2207/01

  Composition gradients · CPC title

• C22C29/14

  based on borides · CPC title

• B22F3/15

  Hot isostatic pressing · CPC title