Method for fabricating a ceramic material

Patent metadata

Field	Value
Publication number	US-11739027-B2
Application number	US-202016791119-A
Country	US
Kind code	B2
Filing date	Feb 14, 2020
Priority date	Oct 12, 2011
Publication date	Aug 29, 2023
Grant date	Aug 29, 2023

Abstract

A ceramic article includes a ceramic matrix composite that has a porous reinforcement structure and a ceramic matrix within pores of the porous reinforcement structure. The ceramic matrix composite includes a surface zone comprised of an exterior surface of the ceramic matrix composite and pores that extend from the exterior surface into the ceramic matrix composite. A glaze material seals the surface zone within the pores of the surface zone and on the exterior surface of the surface zone as an exterior glaze layer on the ceramic matrix composite. The glaze material is a glass or glass-ceramic material. The ceramic matrix composite includes an interior zone under the surface zone, and the interior zone is free of any of the glaze material and has a greater porosity than the surface zone.

First claim

What is claimed is:

1. A ceramic article comprising:
a ceramic matrix composite including a porous reinforcement structure and a ceramic matrix within pores of the porous reinforcement structure, the ceramic matrix composite including a surface zone comprised of an exterior surface of the ceramic matrix composite and pores that extend from the exterior surface into the ceramic matrix composite;
a glaze material sealing the surface zone within the pores of the surface zone and on the exterior surface of the surface zone as an exterior glaze layer on the ceramic matrix composite, wherein the glaze material is a glass-ceramic material, and the ceramic matrix composite including an interior zone under the surface zone, the interior zone being free of any of the glaze material and having a greater porosity than the surface zone;
wherein the glaze material defines a distinct border between the interior zone that has no glaze material and the surface zone that has the glaze material; and
wherein the glaze material comprises a glass-ceramic material that includes at least one rare earth metal from La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, including Sc, Y, and Hf, and combinations thereof.

2. The ceramic article as recited in claim 1 , wherein the glaze material includes at least one rare earth metal from Ce, Nd, Gd, Dy, Yb, including Y and Hf, and combinations thereof.

3. The ceramic article as recited in claim 1 , wherein the glaze material includes at least one element from boron, barium, calcium, magnesium, lithium, sodium, potassium, aluminum, phosphorus, strontium, zinc, and combinations thereof.

4. The ceramic article as recited in claim 1 , wherein the glaze material includes a nucleating agent forming crystalline phases with application of a heat treatment.

5. The ceramic article as recited in claim 4 , wherein the nucleating agent includes zirconium or a compound containing zirconium.

6. The ceramic article as recited in claim 1 , wherein the glaze material comprises a glass-ceramic from one of Li 2 O x-Al 2 O 3 y-nSiO 2 -System (LAS-System), MgO x-Al 2 O 3 y-nSiO 2 -System (MAS-System), ZnO x-Al 2 O 3 y-nSiO 2 -System (ZAS-System), CaO x-Al 2 O 3 y-nSiO 2 -System (CAS), BaO x-MgO y-Al 2 O 3 z-nSiO 2 -System (BMAS-System), CaO x-MgO y-Al 2 O 3 z-nSiO 2 -System (CMAS-System), BaO x-Al 2 O 3 y-nSiO 2 -System (BAS-System), SrO x-Al 2 O 3 y-nSiO 2 -System (SAS-System), and REO-x-Al 2 O 3 -nSiO 2 -Systems, where REO are oxides of the rare earth metals.

7. The ceramic article as recited in claim 6 , wherein the glaze material includes at least one element from Ce, Nd, Ti, Gd, Y, Dy, Yb, Hf, and combinations thereof.

8. The ceramic article as recited in claim 7 , wherein the glaze material comprises a glass-ceramic from at least one of BaO x-MgO y-Al 2 O 3 z-nSiO 2 -System (BMAS-System), SrO x-Al 2 O 3 y-nSiO 2 -System (SAS-System), and REO-x-Al 2 O 3 -nSiO 2 -Systems, where REO are oxides of the rare earth metals.

9. The ceramic article as recited in claim 8 , wherein the glaze material includes at least one element from Ce, Hf, Gd, Yb, and combinations thereof.

10. The ceramic article as recited in claim 1 , wherein the glaze material includes at least one element from boron, barium, calcium, magnesium, strontium and combinations thereof and at least one element from lithium, sodium, potassium, aluminum, phosphorus, zinc, and combinations thereof.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Sheedy Paul
• Schmidt Wayde R
• Kashyap Tania Bhatia

Classifications

• C04B41/86

  Glazes; Cold glazes · CPC title

• C04B41/5022

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

• C04B41/009

  characterised by the material treated · CPC title

• C04B41/0072

  Heat treatment · CPC title

• C03C2209/00

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