Joining material with silicon carbide particles and reactive additives

Patent metadata

Field	Value
Publication number	US-12180122-B2
Application number	US-202117559277-A
Country	US
Kind code	B2
Filing date	Dec 22, 2021
Priority date	Dec 22, 2021
Publication date	Dec 31, 2024
Grant date	Dec 31, 2024

Abstract

In some examples, a method including forming a layer of a slurry composition between a first ceramic or CMC part and a second ceramic or CMC part. The slurry composition includes a carrier material; and a plurality of solid particles in the carrier material. The plurality of solid particles includes first silicon carbide (SiC) particles defining a first average particle size, second SiC particles defining a second average particles size that is less than the first average particles size, and reactive additive particles. The method includes heating the layer of slurry composition to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles, wherein the fused layer of the slurry composition forms a joint layer that joins the first ceramic or CMC part to the second ceramic or CMC part.

First claim

What is claimed is:

1. A method comprising:
forming a layer of a slurry composition between a first ceramic or ceramic matrix composite (CMC) part and a second ceramic or CMC part, wherein the slurry composition comprises:
a carrier material; and
a plurality of solid particles in the carrier material, wherein the plurality of solid particles comprises:
a plurality of first silicon carbide (SiC) particles defining a first average particle size,
a plurality of second SiC particles defining a second average particles size that is less than the first average particles size, and
a plurality of reactive additive particles, wherein the plurality of additive particles has a melting temperature that is less than the plurality of first SiC particles and the plurality of second SiC particles; and

heating the layer of slurry composition to a temperature below a melting temperature of the plurality of reactive additive particles to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles, wherein the fused layer of the slurry composition forms a joint layer that joins the first ceramic or CMC part to the second ceramic or CMC part.

2. The method of claim 1 , wherein heating the layer of slurry composition comprises at least one of brazing or sintering the layer of slurry without melting the plurality of reactive additive particles, the plurality of first SiC particles and the plurality of second SiC particles.

3. The method of claim 1 , wherein the heating the layer of slurry composition is configured such that the additive particles react with silica on a respective surface of at least one of the plurality of first SiC particles or the plurality of second SiC particles to form a silicate ternary phase in the joint layer.

4. The method of claim 1 , wherein the plurality of solid particles in the carrier material includes at least about 85 volume percent of a combination of the plurality of first SiC particles and the plurality of second SiC particles.

5. The method of claim 1 , wherein the plurality of solid particles in the carrier material includes at least about 5 volume percent of the plurality of additive particles.

6. The method of claim 1 , wherein the plurality of first SiC particles includes at least about 50 percent alpha phase SiC particles.

7. The method of claim 1 , wherein the plurality of second SiC particles includes at least about 50 percent beta phase SiC particles.

8. The method of claim 1 , wherein the slurry composition includes at least 35 volume percent solid loading of the plurality of solid particles.

9. The method of claim 1 , wherein heating the layer of slurry composition includes removing the carrier material from the layer of slurry composition.

10. The method of claim 1 , wherein the plurality of additive particles includes at least one of yttria or alumina.

11. The method of claim 1 , wherein heating the layer of slurry composition includes heating the layer of slurry composition without applying additional pressure during the heating.

12. The method of claim 1 , wherein the plurality of first SiC particles comprise coarse particles having the first average particle size of about 7.0 μm to about 17 μm, and wherein the plurality of second SiC particles comprise fine particles having the second average particle size of about 0.7 μm to about 4.5 μm.

13. The method of claim 1 , wherein the plurality of solid particles comprises a plurality of third SiC particles defining a third average particle size that is less than the first average particle size and the second average particle size.

14. The method of claim 13 , wherein the third average particle size is about 40 nanometers (nm) to about 100 nm.

15. The method of claim 1 , wherein the plurality of reactive additive particles includes a plurality of first reactive additive particles and a plurality of second reactive additive particles different from the plurality of reactive additive particles, wherein heating the layer of slurry composition to the temperature below the melting temperature of the plurality of reactive additive particles to react the plurality of reactive additive particles comprises heating the layer of slurry composition to the temperature below the melting temperature of the plurality of reactive additive particles to react the plurality of first reactive additive particles with the plurality of second reactive additive particles without melting the plurality of first reactive additive particles and the plurality of second reactive additive particles.

16. The method of claim 15 , wherein the plurality of first reactive additive particles comprise yttria and the plurality of second reactive additive particles comprise alumina.

17. The method of claim 1 , wherein heating the layer of slurry composition to a temperature below a melting temperature of the plurality of reactive additive particles to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles includes heating the layer of slurry composition to the temperature that cause the plurality of reactive additive particles to diffuse and react with oxide on surfaces of the plurality of first SiC particles and the plurality of second SiC particles but not cause the plurality of reactive additive particles to melt.

18. The method of claim 1 , wherein heating the layer of slurry composition to a temperature below a melting temperature of the plurality of reactive additive particles to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles includes heating the layer of slurry composition to the temperature that cause the plurality of reactive additive particles to react with each other to form an intergranular phase at grain boundaries in the joint layer but not cause the plurality of reactive additive particles to melt.

19. The method of claim 1 , wherein, following the heating of the layer of the slurry composition, the joint layer includes a primary phase of SiC and an intergranular secondary phase formed by the reaction of the plurality of reactive additive particles with each other.

20. An assembly comprising:
a first ceramic or ceramic matrix composite (CMC) part;
a second ceramic or CMC part adjacent to the first ceramic or ceramic matrix composite part; and
layer of slurry composition between the first ceramic or CMC part and the second ceramic or CMC part, wherein the slurry composition comprises:
a carrier material; and
a plurality of solid particles in the carrier material, wherein the plurality of solid particles comprises:
a plurality of first silicon carbide (SiC) particles defining a first average particle size,
a plurality of second SiC particles defining a second average particles size that is less than the first average particles size, and
a plurality of reactive additive particles, wherein the plurality of additive particles has a melting temperature that is less than the plurality of first SiC particles and the plurality of second SiC particles,

wherein the plurality of reactive additive particles are configured to, upon heating to a temperature below a melting point of the plurality of reactive additive particles, react to fuse the plurality of first SiC particles and the plurality

Assignees

• Rolls Royce High Temperature Composites Inc

Inventors

• Sellappan Pathikumar
• Kedir Nesredin
• Harris Stephen Isaiah

Classifications

• C04B2237/09

  wherein the active component for bonding is not the largest fraction of the interlayer · CPC title

• C04B2237/60

  Forming at the joining interface or in the joining layer specific reaction phases or zones, e.g. diffusion of reactive species from the interlayer to the substrate or from a substrate to the joining interface, carbide forming at the joining interface · CPC title

• C04B2237/38

  Fiber or whisker reinforced · CPC title

• C04B2237/84

  Joining of a first substrate with a second substrate at least partially inside the first substrate, where the bonding area is at the inside of the first substrate, e.g. one tube inside another tube · CPC title

• C04B2237/083

  Carbide interlayers, e.g. silicon carbide interlayers · CPC title