Contact joule heating for sintering high temperature coatings

Patent metadata

Field	Value
Publication number	US-12071383-B2
Application number	US-202117302009-A
Country	US
Kind code	B2
Filing date	Apr 21, 2021
Priority date	Apr 21, 2021
Publication date	Aug 27, 2024
Grant date	Aug 27, 2024

Abstract

A method for forming a high temperature coating includes forming a pre-sintered ceramic coating on a ceramic composite substrate. The pre-sintered ceramic coating includes a plurality of ceramic particles. The method further includes sintering at least a portion of the pre-sintered ceramic coating by heating the portion of the pre-sintered ceramic coating to a sintering temperature of the plurality of ceramic particles using joule heating. The sintering temperature is greater than about 1000 degrees Celsius (° C.).

First claim

What is claimed is:

1. A method, comprising:
forming a pre-sintered ceramic coating on a ceramic composite substrate, wherein the pre-sintered ceramic coating comprises a plurality of ceramic particles;
contacting at least a portion of the pre-sintered ceramic coating with one or more contact electrical elements;
delivering an electrical current through the one or more contact electrical elements to the ceramic composite substrate; and
sintering at least the portion of the pre-sintered ceramic coating by heating the portion of the pre-sintered ceramic coating to a sintering temperature of the plurality of ceramic particles using joule heating induced in the ceramic composite substrate by the delivery of the electrical current through the one or more contact electrical elements to the ceramic composite substrate,
wherein the sintering temperature is greater than about 1000 degrees Celsius (° C.).

2. The method of claim 1 , further comprising:
contacting the portion of the pre-sintered ceramic coating with one or more contact heating elements; and
powering the one or more contact heating elements to heat the portion of the pre-sintered ceramic coating.

3. The method of claim 2 , wherein the one or more contact heating elements comprise one or more high temperature electrode heating elements.

4. The method of claim 2 , further comprising moving the pre-sintered ceramic coating relative to the one or more contact heating elements to cause the one or more contact heating elements to contact a different portion of the pre-sintered ceramic coating.

5. The method of claim 2 , further comprising compressing the portion of the pre-sintered ceramic coating while heating the portion of the pre-sintered ceramic coating.

6. The method of claim 5 , wherein compressing the portion of the pre-sintered ceramic coating comprises compressing the portion of the pre-sintered ceramic using a roller, wherein the method further comprises advancing the roller to heat another portion of the pre-sintered ceramic coating.

7. The method of claim 1 , wherein the plurality of ceramic particles comprises at least one of a carbide ceramic, a boride ceramic, or a nitride ceramic.

8. The method of claim 1 , wherein the plurality of ceramic particles comprises a rare earth disilicate ceramic.

9. The method of claim 1 , further comprising forming a crystallized metal carbide undercoat on a surface of the ceramic composite substrate.

10. The method of claim 1 , wherein forming the pre-sintered ceramic coating further comprises applying a ceramic mixture on a surface of the ceramic composite substrate, wherein the ceramic mixture includes the plurality of ceramic particles.

Assignees

• Honeywell Int Inc

Inventors

• Mehr Mehrad
• Jadidian Bahram

Classifications

• C04B2235/665

  Local sintering, e.g. laser sintering · CPC title

• C04B2235/6581

  Total pressure below 1 atmosphere, e.g. vacuum · CPC title

• C04B2235/3817

  Carbides · CPC title

• C04B2235/3427

  Silicates other than clay, e.g. water glass · CPC title

• C04B41/89

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