Method for fabricating a ceramic material

Patent metadata

Field	Value
Publication number	US-2017275211-A1
Application number	US-201715618874-A
Country	US
Kind code	A1
Filing date	Jun 9, 2017
Priority date	Oct 12, 2011
Publication date	Sep 28, 2017
Grant date	—

Abstract

A ceramic article includes a ceramic matrix composite that has a porous reinforcement structure and a ceramic matrix within pores of the porous reinforcement structure. The ceramic matrix composite includes a surface zone and a glaze material within pores of the surface zone and on an exterior side of the surface zone as an exterior glaze layer.

First claim

What is claimed is:

1 . A ceramic article comprising:
a ceramic matrix composite including a porous reinforcement structure and a ceramic matrix within pores of the porous reinforcement structure, the ceramic matrix composite including a surface zone; and a glaze material within pores of the surface zone and on an exterior side of the surface zone as an exterior glaze layer on the ceramic matrix composite.

2 . The ceramic article as recited in claim 1 , wherein the glaze material is free silicon.

3 . The ceramic component as recited in claim 1 , wherein the glaze material is a free metal selected from the group consisting of boron, titanium, vanadium, chromium, zirconium, niobium, molybdenum, ruthenium, rhodium, hafnium, tantalum, tungsten, rhenium, osmium, iridium and combinations thereof.

4 . The ceramic component as recited in claim 3 , wherein the free metal is selected from the group consisting of boron, zirconium, and combinations thereof.

5 . The ceramic component as recited in claim 1 , wherein the free metal is selected from the group consisting of vanadium, molybdenum, hafnium, tantalum, and combinations thereof.

6 . The ceramic article as recited in claim 1 , where the glaze material contains free silicon and a free metal selected from the group consisting of boron, titanium, vanadium, chromium, zirconium, niobium, molybdenum, ruthenium, rhodium, hafnium, tantalum, tungsten, rhenium, osmium, iridium and combinations thereof.

7 . The ceramic component as recited in claim 6 , wherein the free metal is selected from the group consisting of boron, zirconium, and combinations thereof.

8 . The ceramic component as recited in claim 6 , wherein the free metal is selected from the group consisting of vanadium, molybdenum, hafnium, tantalum, and combinations thereof.

9 . The ceramic article as recited in claim 1 , wherein the glaze material is a ceramic material.

10 . The ceramic article as recited in claim 9 , wherein the ceramic material is at least partially amorphous.

11 . The ceramic article as recited in claim 1 , wherein the glaze material is a Borosilicate glass (BSG) of composition, by weight, Boron Oxide, B 2 O 3 , 10-30%; Aluminum Oxide, Al 2 O 3 , 0-4%; Sodium Oxide, Na 2 O, 0-8%; and Silicon Dioxide, SiO 2 , 65-85%.

12 . The ceramic article as recited in claim 1 , wherein the glaze material is a Barium Magnesium Alumino Silicate (BMAS) glass of composition, by weight, Barium Oxide, BaO, 12-16%; Magnesium Oxide, MgO, 5-10%; Boron Oxide, B 2 O 3 , 0-4%; Aluminum Oxide, Al 2 O 3 , 25-35%; and Silicon Dioxide, SiO 2 , 45-55%.

13 . The ceramic article as recited in claim 1 , wherein the ceramic matrix composite includes an interior zone under the surface zone, and the interior zone is free of any of the glaze material and has a greater porosity than the surface zone.

14 . The ceramic article as recited in claim 1 , wherein the glaze material on the exterior side is a solid, continuous layer.

15 . The ceramic article s recited in claim 1 , wherein the glaze material is a silicate-based glass or a glass-ceramic that includes at least one rare earth metal from La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Sc, Y, and Hf.

16 . A ceramic article comprising:
a ceramic matrix composite including a porous reinforcement structure and a ceramic matrix within pores of the porous reinforcement structure, the ceramic matrix composite including a surface zone; and a glaze material within pores of the surface zone and on an exterior side of the surface zone as an exterior glaze layer on the ceramic matrix composite, the glaze material including free silicon and at least one other free metal.

17 . The ceramic component as recited in claim 16 , wherein the free metal selected from the group consisting of boron, titanium, vanadium, chromium, zirconium, niobium, molybdenum, ruthenium, rhodium, hafnium, tantalum, tungsten, rhenium, osmium, iridium and combinations thereof.

18 . The ceramic component as recited in claim 17 , wherein the free metal is selected from the group consisting of boron, zirconium, and combinations thereof.

19 . The ceramic component as recited in claim 17 , wherein the free metal is selected from the group consisting of vanadium, molybdenum, hafnium, tantalum, and combinations thereof.

Assignees

• United Technologies Corp

Inventors

• Sheedy Paul
• Schmidt Wayde R
• Kashyap Tania Bhatia

Classifications

• C04B2235/5244

  Silicon carbide · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B35/76

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• C04B35/62842

  Metals · CPC title

• C04B2235/48

  Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins · CPC title