Adaptive surface texturing for ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-12371389-B2
Application number	US-202217665069-A
Country	US
Kind code	B2
Filing date	Feb 4, 2022
Priority date	Feb 4, 2022
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

An adaptive surface texturing method is provided for use with a part formed of ceramic matrix composites (CMCs) to be coated with an environmental barrier coating (EBC). The method includes coating a CMC surface of the part with an initial coating, determining a contour and an undulation pattern of the CMC surface and designing a texturing pattern to follow the contour and the undulation pattern and to be formed in the initial coating based on a thickness of the initial coating and an average particle size of a slurry of the EBC.

First claim

What is claimed is:

1. An adaptive surface texturing method for use with a part formed of ceramic matrix composites (CMCs) to be coated with an environmental barrier coating (EBC), the method comprising:
coating a CMC surface of the part with an initial coating, the CMC surface comprising fibers that are woven together;
determining a macroscopic contour and microscopic undulation pattern of the CMC surface, the microscopic undulation pattern being formed by the fibers that are woven together; and
designing a texturing pattern to follow the macroscopic contour and the microscopic undulation pattern of the CMC surface and to be formed in the initial coating based on a thickness of the initial coating and an average particle size of a slurry of the EBC.

2. The method according to claim 1 , wherein the initial coating comprises silicon carbide and has a thickness of about 75-250 microns.

3. The method according to claim 1 , wherein the determining comprises an optical measurement of the CMC surface from which the macroscopic contour and the microscopic undulation pattern are derived.

4. The method according to claim 1 , wherein:
the fibers comprise first fibers having a first orientation and second fibers having a second orientation,
the first fibers and the second fibers form a weaving pattern defining the microscopic undulation pattern, and
the texturing pattern comprises:
first grooves to be formed in the initial coating at first locations where the first fibers overlie the second fibers and to have long axes aligned with orientations of the first fibers; and
second grooves to be formed in the initial coating at second locations where the second fibers overlie the first fibers and to have long axes aligned with orientations of the second fibers.

5. The method according to claim 4 , wherein the designing comprises;
restricting a depth of the first grooves to be shallower than the thickness of the initial coating at the first locations; and
restricting a depth of the second grooves to be shallower than the thickness of the initial coating at the second locations.

6. The method according to claim 4 , wherein the designing comprises establishing a critical dimension of the first grooves and of the second grooves in accordance with the average particle size of the EBC.

7. The method according to claim 4 , wherein the designing comprises;
sizing the first grooves at each one of the first locations to decrease in length with decreasing distance to adjacent ones of the second locations; and
sizing the second grooves at each one of the second locations to decrease in length with decreasing distance to adjacent ones of the first locations.

8. The method according to claim 4 , wherein the designing comprises;
arranging the first grooves in accordance with the orientation of the first fibers at each of the first locations in the microscopic undulation pattern; and
arranging the second grooves in accordance with the orientation of the second fibers at each of the second locations in the microscopic undulation pattern.

9. The method according to claim 1 , further comprising:
imparting the texturing pattern to the initial coating; and
applying the EBC following the imparting.

10. An adaptive surface texturing method for use with a part formed of ceramic matrix composites (CMCs) to be coated with an environmental barrier coating (EBC), the method comprising:
completing a formation of the part and a chemical vapor infiltration (CVI) process to initially coat a CMC surface thereof with an initial coating, the CMC surface comprising fibers that are woven together;
determining a macroscopic contour and aft microscopic undulation pattern of the CMC surface, the microscopic undulation pattern being formed by the fibers that are woven together; and
designing a texturing pattern to follow the macroscopic contour and the microscopic undulation pattern of the CMC surface and to be formed in the initial coating based on a thickness of the initial coating and an average particle size of a slurry of the EBC.

11. The method according to claim 10 , wherein the initial coating comprises silicon carbide and has a thickness of about 75-250 microns.

12. The method according to claim 10 , wherein the determining comprises optical measurement of the CMC surface from which the macroscopic contour and the microscopic undulation pattern are derived.

13. The method according to claim 10 , wherein:
the fibers comprise first fibers having a first orientation and second fibers having a second orientation,
the first fibers and the second fibers form a weaving pattern defining the microscopic undulation pattern, and
the texturing pattern comprises:
first grooves to be formed in the initial coating at first locations where the first fibers overlie the second fibers and to have long axes aligned with orientations of the first fibers; and
second grooves to be formed in the initial coating at second locations where the second fibers overlie the first fibers and to have long axes aligned with orientations of the second fibers.

14. The method according to claim 13 , wherein the designing comprises;
restricting a depth of the first grooves to be shallower than the thickness of the initial coating at the first locations; and
restricting a depth of the second grooves to be shallower than the thickness of the initial coating at the second locations.

15. The method according to claim 13 , wherein the designing comprises establishing a critical dimension of the first grooves and of the second grooves in accordance with the average particle size of the EBC.

16. The method according to claim 13 , wherein the designing comprises;
sizing the first grooves at each one of the first locations to decrease in length with decreasing distance to adjacent ones of the second locations; and
sizing the second grooves at each one of the second locations to decrease in length with decreasing distance to adjacent ones of the first locations.

17. The method according to claim 13 , wherein the designing comprises;
arranging the first grooves in accordance with the orientation of the first fibers at each of the first locations in the microscopic undulation pattern; and
arranging the second grooves in accordance with the orientation of the second fibers at each of the second locations in the microscopic undulation pattern.

18. The method according to claim 10 , further comprising:
imparting the texturing pattern to the initial coating; and
applying the EBC following the imparting.

19. A ceramic matrix composite (CMC) surface of a part having a macroscopic contour formed of CMCs; the CMC surface comprising:
fibers weaved with one another to form a microscopic undulation pattern;
an initial coating having a texturing pattern formed therein; and
an environmental barrier coating (EBC) applied to the initial coating,
wherein the texturing pattern follows the macroscopic contour and the microscopic undulation pattern of the CMC surface and comprises grooves which are shallower than a thickness of the initial coating and which have a critical dimension that exceeds an average particle size of a slurry of the EBC.

20. The CMC surface according to claim 19 , wherein:
the fibers comprise first fibers having a first orientation and second fibers having a second orientation,
the first fibers and the second fibers form a weaving pattern defining the microscopic undulation pattern, and
the grooves comprise:
first grooves formed in the initial coati

Assignees

• Rtx Corp

Inventors

• Wang Zhigang
• Tang Xia
• Beals James T
• Srinivasan Gajawalli V
• Riehl John D
• Hazel Brian T
• Litton David A

Classifications

• F01D5/288

  Protective coatings for blades · CPC title

• C04B41/89 Primary

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

• C04B41/52

  Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation} · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title

• B28B1/00

  Producing shaped {prefabricated} articles from the material (using presses B28B3/00; shaping on moving conveyors B28B5/00; producing tubular articles B28B21/00 {; producing articles with embedded elements B28B23/00}) · CPC title