Method for coating a refractory alloy part, and the part thus coated

Patent metadata

Field	Value
Publication number	US-2024246140-A1
Application number	US-202218565998-A
Country	US
Kind code	A1
Filing date	May 30, 2022
Priority date	Jun 1, 2021
Publication date	Jul 25, 2024
Grant date	—

Abstract

A method includes coating of one or more zones of the refractory alloy part, using a treatment composition including one or more types of preceramic polymer, a solvent and one or more active fillers, and heat treating the coated refractory alloy part, the heat treatment allowing to partially convert the preceramic polymer to form a ceramic layer, the active filler forming on a surface of the refractory alloy part, one or more ternary alloys and forming a continuous layer between the surface of the refractory alloy part and the ceramic layer obtained by conversion. The heat treatment forms a continuous layer of the ternary alloy. The treatment composition includes, relative to the total weight of the treatment composition, a weight proportion of between 40% and 66% of the one or more active fillers, and an active filler/preceramic polymer weight ratio is greater than or equal to 2.

First claim

1 . A method for coating a refractory alloy part, comprising:
coating of at least one zone of the refractory alloy part, using a treatment composition comprising at least one type of preceramic polymer, a solvent and at least one active filler, heat treating the refractory alloy part coated with the treatment composition, the heat treatment allowing to at least partially convert the preceramic polymer to form a ceramic layer,
the active filler being chosen to form, by solid or liquid diffusion, on a surface of the refractory alloy part, at least one alloy which is at least ternary resulting from a co-reactivity of the active filler with the refractory alloy part and the preceramic polymer, the at least ternary alloy forming a continuous layer between the surface of the refractory alloy part and the ceramic layer obtained by conversion,
wherein the heat treatment is carried out so as to form a continuous layer of the at least ternary alloy, which protects the refractory alloy part from oxidation, wherein the treatment composition comprises, relative to the total weight of the treatment composition, a weight proportion of between 40% and 66% of at least one active filler,

and
wherein an active filler/preceramic polymer weight ratio is greater than or equal to 2.

2 . The method according to claim 1 , wherein the treatment composition comprises, relative to the total weight of the treatment composition, the weight proportion of between 45% and 60% of at least one active filler and wherein the active filler/preceramic polymer weight ratio is comprised between 2 and 3.

3 . The method according to claim 1 , wherein said treatment composition comprises, relative to the total weight of the treatment composition, the weight proportion of between 55% and 60% of at least one active filler, and
wherein the active filler/preceramic polymer weight ratio is comprised between 2 and 2.5.

4 . The method according to claim 1 , wherein the at least one active filler is selected from silicon powder, aluminum powder, iron powder, copper powder, cobalt powder, nickel powder, lanthanum powder, germanium powder, zirconium powder, chromium powder, titanium powder, hafnium powder, lanthanum powder and rhenium powder.

5 . The method according to claim 1 , wherein the preceramic polymer is selected from siloxanes, polysiloxanes with high ceramization yield which are converted into silica (SiO 2 ) or silicon oxycarbide (Si—O—C) by pyrolysis, polysilazanes or polycarbosilanes.

6 . The method according to claim 1 , wherein the treatment composition further comprises passive fillers, configured to modulate a thermal expansion coefficient of the at least ternary alloy layer, so as to have a difference between a thermal expansion coefficient of the refractory alloy part and the thermal expansion coefficient of the at least ternary alloy layer less than 3.10 −6 K −1 .

7 . The method according to claim 1 , wherein the coating comprises at least one first coating step and one second consecutive coating step, and the heat treatment comprises at least one heat treatment step carried out between the first coating step and the second consecutive coating step, the heat treatment step being a crosslinking step for crosslinking the preceramic polymer(s), configured to generate an infusible polymer network capable of withstanding subsequent pyrolysis steps, the second consecutive coating step being applied to obtain a thicker treatment composition layer.

8 . The method according to claim 7 , wherein the treatment composition used during the second consecutive coating step has a viscosity lower than a viscosity of the treatment composition used during the first coating step.

9 . The method according to one of claim 7 , wherein the crosslinking step is carried out in the presence of air at a temperature greater than or equal to a highest crosslinking temperature among the different crosslinking temperatures of the different species of preceramic polymer of the treatment solution.

10 . The method according to claim 1 , wherein the heat treating comprises:
crosslinking at a first temperature configured to evaporate the solvent and thus accelerate the crosslinking, performing a conversion carried out at a second temperature, higher than the first, configured to convert the preceramic polymer into ceramic and eliminate the organic species, so as to obtain a ceramic having an amorphous structure, and structuring carried out at a third temperature, higher than the second temperature, configured to convert the ceramic with an amorphous structure into ceramic having a crystalline structure.

11 . The method according to claim 1 , wherein the heat treating is carried out under a controlled atmosphere so as to avoid oxidation of the refractory alloy part, while having an oxygen partial pressure sufficient to ensure the conversion of the preceramic polymer into oxycarbide ceramic or oxide ceramic.

12 . The method according to claim 1 , wherein the ceramic layer obtained by conversion is removed after the heat treatment, by mechanical or chemical action to leave only the at least ternary alloy layer.

13 . A refractory alloy part, obtained by the coating method according to claim 1 ,
wherein the refractory alloy part is coated with a continuous layer of at least one alloy which is at least ternary and which results from the co-reactivity of the active filler with the refractory alloy part and the preceramic polymer, and with a ceramic layer,
and
the continuous layer of at least one alloy which is at least ternary being disposed between the refractory alloy part and the ceramic layer.

14 . The refractory alloy part according to claim 13 , wherein the refractory alloy part is a foundry core made of refractory alloy.

15 . The refractory alloy part according to claim 13 , wherein the refractory alloy part is based on molybdenum.

16 . The method according to claim 1 , wherein the refractory alloy part is based on molybdenum.

Assignees

• Safran
• Commissariat Energie Atomique

Inventors

• Soulier Mathieu
• Laucournet Richard
• Bancillon Jacky
• Montani Alexander
• Bechelany Mirna
• Jaquet Virginie
• Saboundji Amar

Classifications

• C23C28/34

  including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates · CPC title

• B22C9/10 Primary

  Cores; Manufacture or installation of cores {(breaker cores B22C9/084)} · CPC title

• C23C24/082

  without intermediate formation of a liquid in the layer · CPC title

• B22C3/00

  Selection of compositions for coating the surfaces of moulds, cores, or patterns · CPC title

• C23C28/321

  with at least one metal alloy layer · CPC title