Method and system for molded coating on CMC

Patent metadata

Field	Value
Publication number	US-12311574-B2
Application number	US-202117401721-A
Country	US
Kind code	B2
Filing date	Aug 13, 2021
Priority date	Aug 14, 2020
Publication date	May 27, 2025
Grant date	May 27, 2025

Abstract

A method of forming a coating includes providing a mold that has a flexible wall that defines a mold cavity, inserting a component that is to be coated into the mold cavity, the component having a component surface roughness and there being a coating gap defined between the component and the flexible wall of the mold cavity, introducing a molding slurry into the mold cavity, the molding slurry filling the coating gap and contacting the component so as to overcoat the component surface roughness, solidifying the molding slurry to form a green coating on the component, and consolidating the green coating to form a final coating on the component, the final coating having a coating surface roughness that is less than the component surface roughness.

First claim

What is claimed is:

1. A method of forming a coating, comprising:
providing a mold that has a flexible wall formed of silicone elastomer that defines a mold cavity;
inserting a component that is to be coated into the mold cavity, the component having a component surface roughness and there being a coating gap defined between the component and the flexible wall of the mold cavity;
introducing a molding slurry into the mold cavity, the molding slurry including a carrier liquid and powder particles, the molding slurry filling the coating gap and contacting the component so as to overcoat the component surface roughness;
solidifying the molding slurry to form a green coating of powder particles on the component; and
consolidating the green coating to form a final coating on the component, the final coating having a coating surface roughness that is less than the component surface roughness.

2. The method as recited in claim 1 , wherein the inserting includes situating the component in the mold cavity such that the coating gap is of uniform thickness.

3. The method as recited in claim 1 , wherein the inserting includes using one or more bumpers in the mold cavity to space the component from the flexible wall.

4. The method as recited in claim 3 , wherein the component has one or more cooling holes, and the one or more bumpers plug the one or more cooling holes.

5. The method as recited in claim 1 , wherein the component has a cooling hole that is plugged.

6. The method as recited in claim 1 , wherein the solidifying includes heating the molding slurry while in the coating gap in the mold cavity.

7. The method as recited in claim 1 , wherein the mold includes at least one injection port and at least one vent port.

8. The method as recited in claim 1 , wherein the consolidating includes heating the green coating to a temperature at which the powder particles sinter.

9. The method as recited in claim 1 , wherein the mold is formed of elastomer.

10. The method as recited in claim 1 , wherein the component is a gas turbine engine component formed of ceramic matrix composite.

11. The method as recited in claim 8 , wherein the component is a ceramic matrix composite.

12. The method as recited in claim 11 , wherein the powder particles include at least one of silica particles or siliconoxycarbide particles.

Assignees

• Raytheon Tech Corp
• Rtx Corp

Inventors

• Liu Xuan
• Beals James T
• Tang Xia
• Hawkes Justin R
• Sudre Olivier H
• Werkheiser William F
• Hazel Brian T
• Jackson Richard Wesley

Classifications

• B29C2037/0035

  the coating being applied as liquid, gel, paste or the like · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title

• F01D5/288

  Protective coatings for blades · CPC title

• F01D5/147

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• C04B41/87

  Ceramics · CPC title