Repair process using networked ceramic nanofibers

Patent metadata

Field	Value
Publication number	US-12076885-B2
Application number	US-202117174842-A
Country	US
Kind code	B2
Filing date	Feb 12, 2021
Priority date	Feb 8, 2019
Publication date	Sep 3, 2024
Grant date	Sep 3, 2024

Abstract

A repair process for an article such as an airfoil includes providing an article that has a substrate and a ceramic barrier coating disposed on the substrate, where the ceramic barrier coating has a damaged region, abrading the damaged region to provide dimple in the ceramic barrier coating, wherein a remaining region of the ceramic barrier coating adjacent the dimple remains intact, and depositing a patch of networked ceramic nanofibers in the dimple.

First claim

What is claimed is:

1. An article comprising:
a substrate;
a ceramic barrier coating disposed on the substrate, the ceramic barrier coating including a dimple, the ceramic barrier coating having a porous columnar microstructure that includes microstructural columns that define elongated pores there between; and
a patch of networked ceramic nanofibers disposed in the dimple, the networked ceramic nanofibers comprising filaments that are non-linear and intertwined so as to form a porous network, the filaments being bonded together at locations where the filaments contact each other, and wherein the networked ceramic nanofibers extend into the elongated pores and interlock with the elongated pores and surface roughness of the dimple such that the networked ceramic nanofibers are secured to the ceramic barrier coating.

2. The article as recited in claim 1 , wherein the ceramic nanofibers are selected from the group consisting of yttria stabilized zirconia, gadolinia zirconate, and combinations thereof.

3. The article as recited in claim 1 , wherein the ceramic barrier coating is selected from the group consisting of yttria stabilized zirconia, gadolinia zirconate, and combinations thereof.

4. The article as recited in claim 1 , wherein the ceramic nanofibers are selected from the group consisting of yttria stabilized zirconia, gadolinia zirconate, and combinations thereof, and the ceramic barrier coating is selected from the group consisting of yttria stabilized zirconia, gadolinia zirconate, and combinations thereof.

5. The article as recited in claim 1 , wherein the ceramic nanofibers include zirconium oxide.

6. The article as recited in claim 1 , wherein the filaments are flexible.

7. The article as in claim 1 , wherein the substrate is an airfoil.

Assignees

• Raytheon Tech Corp
• Rtx Corp

Inventors

• Ding Zhongfen

Classifications

• C23C28/042

  including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides · CPC title

• F01D5/288

  Protective coatings for blades · CPC title

• C23C4/11 Primary

  Oxides · CPC title

• F05D2300/614

  Fibres or filaments · CPC title

• F05D2300/20

  Oxide or non-oxide ceramics · CPC title