Refractory materials

Patent metadata

Field	Value
Publication number	US-12545627-B2
Application number	US-202318468443-A
Country	US
Kind code	B2
Filing date	Sep 15, 2023
Priority date	Sep 15, 2023
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

A method includes forming an article from a silicon-rich refractory mixture. The silicon-rich refractory mixture includes a silicon-rich silicon carbide preceramic polymer and a silicon carbide powder. The method includes heating the preform to pyrolyze the silicon-rich silicon carbide preceramic polymer and form a silicon-rich refractory material. The silicon-rich refractory material includes the silicon carbide powder and excess silicon in a silicon carbide matrix. The method further includes heating the silicon-rich refractory material to oxidize at least a portion of the excess silicon and form a reinforced refractory material. The reinforced refractory material includes a silicon dioxide phase at grain boundaries of the silicon carbide powder.

First claim

What is claimed is:

1 . A method comprising:
forming a coating on a substrate, wherein the coating is formed from a silicon-rich refractory mixture that comprises:
a silicon-rich silicon carbide preceramic polymer; and
a silicon carbide powder;
heating the coating to pyrolyze the silicon-rich silicon carbide preceramic polymer and form a silicon-rich refractory material, wherein the silicon-rich refractory material comprises the silicon carbide powder and excess silicon in a polymer-derived silicon carbide matrix; and heating the silicon-rich refractory material to oxidize at least a portion of the excess silicon and form a reinforced refractory material, wherein the reinforced refractory material includes a silicon dioxide phase comprising a boundary phase at grain boundaries of the silicon carbide powder and a pore phase at pores within the polymer-derived silicon carbide matrix.

2 . The method of claim 1 , wherein the polymer-derived silicon carbide matrix defines less than about 10 percent by volume of the reinforced refractory material.

3 . The method of claim 1 , wherein a porosity of the reinforced refractory material has a porosity that is less than or equal to about 5 volume percent (vol. %).

4 . The method of claim 1 , wherein the silicon-rich refractory mixture further comprises silicon powder.

5 . The method of claim 1 , further comprising forming the refractory mixture by at least mixing the silicon-rich silicon carbide preceramic polymer and the silicon carbide powder.

6 . The method of claim 1 , wherein heating the coating further comprises heating the silicon-rich silicon carbide preceramic polymer above a pyrolysis temperature to pyrolyze the silicon-rich silicon carbide preceramic polymer into the polymer-derived silicon carbide matrix.

7 . The method of claim 6 , wherein heating the coating further comprises heating the polymer-derived silicon carbide matrix above a crystallization temperature to crystallize the polymer-derived silicon carbide matrix.

8 . The method of claim 1 , further comprising, prior to forming the coating on the substrate, forming a metal carbide layer on the substrate, wherein the coating is formed on a surface of the metal carbide layer.

9 . The method of claim 8 , wherein forming the metal carbide layer further comprises:
depositing a carbon layer on a surface of the substrate, wherein a melting point of the substrate is greater than or equal to about 1500 degrees Celsius (° C.); applying a metal slurry to a surface of the carbon layer following the deposition of the carbon layer; and reacting a metal of the metal slurry with carbon of the carbon layer to form the metal carbide layer on the substrate.

10 . The method of claim 9 ,
wherein a porosity of the substrate is greater than about 10 percent by volume (vol. %), and wherein a porosity of the metal carbide layer is less than about 5 vol. %.

11 . The method of claim 9 ,
wherein the metal of the metal slurry comprises silicon, and wherein the metal carbide layer comprises silicon carbide.

12 . An article, comprising:
a substrate; and a coating overlying the substrate, wherein the coating comprises a reinforced refractory material comprising:
a polymer-derived silicon carbide matrix;
a silicon carbide powder in the polymer-derived silicon carbide matrix; and
a silicon dioxide phase comprising a boundary phase at grain boundaries of the silicon carbide powder and a pore phase at pores within the polymer-derived silicon carbide matrix.

13 . The article of claim 12 , wherein the polymer-derived silicon carbide matrix comprises less than about 10 percent by volume of the reinforced refractory material.

14 . The article of claim 12 , wherein the silicon dioxide phase comprises less than about 1 percent by volume of the reinforced refractory material.

15 . The article of claim 12 , wherein a porosity of the reinforced refractory material is less than or equal to about 5 volume percent (vol. %).

16 . The article of claim 12 , wherein the reinforced refractory material further comprises silicon powder.

17 . The article of claim 12 , wherein the substrate comprises a component of an aerospace system.

18 . The article of claim 12 , further comprising a metal carbide layer on a surface of the substrate, wherein the coating overlies the metal carbide layer, and wherein a melting point of the substrate is greater than or equal to about 1500 degrees Celsius (° C.).

19 . The article of claim 18 , wherein the metal carbide layer comprises silicon carbide.

20 . The article of claim 18 , wherein the pore phase is discrete and separate from the boundary phase.

Assignees

• Honeywell Int Inc

Inventors

• Mehr Mehrad
• Jadidian Bahram

Classifications

• C04B2235/483

  Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes · CPC title

• C04B2235/9684

  Oxidation resistance · CPC title

• C04B2235/663

  Oxidative annealing · CPC title

• C04B2235/428

  Silicon · CPC title

• C04B2235/9676

  against molten metals such as steel or aluminium · CPC title