Reactive infiltration with silicide forming binary alloys

Patent metadata

Field	Value
Publication number	US-2025382686-A1
Application number	US-202418747331-A
Country	US
Kind code	A1
Filing date	Jun 18, 2024
Priority date	Jun 18, 2024
Publication date	Dec 18, 2025
Grant date	—

Abstract

A gas turbine engine component includes a component including at least one ceramic matrix composite material, the at least one ceramic matrix composite material further includes a ceramic fiber reinforcement containing at least one ceramic fiber or at least one ceramic fiber tow; and a matrix material disposed around and in contact with the at least one ceramic fiber or the at least one ceramic fiber tow; the matrix material contains at least one eutectic alloy, at least one metal-rich alloy, or combinations thereof; either the at least one eutectic alloy or the at least one metal-rich alloy includes silicon and at least one of the following alloy constituents: zirconium, hafnium, tungsten, tantalum, molybdenum, niobium, and iridium; and, either the at least one eutectic alloy or the at least one metal-rich alloy exhibits and possesses a melting point range of approximately 1,250° C. to approximately 1,650° C.

First claim

1 . A gas turbine engine component, comprising:
a component comprising at least one ceramic matrix composite material, the at least one ceramic matrix composite material comprising:
a ceramic fiber reinforcement comprising at least one ceramic fiber or at least one ceramic fiber tow; and
a matrix material disposed around and in contact with the at least one ceramic fiber or the at least one ceramic fiber tow;
wherein the matrix material comprises at least one eutectic alloy, at least one metal-rich alloy, or combinations thereof;
wherein either the at least one eutectic alloy or the at least one metal-rich alloy comprises silicon and at least one of the following alloy constituents: zirconium, hafnium, tungsten, tantalum, molybdenum, niobium, and iridium;
wherein either the at least one eutectic alloy or the at least one metal-rich alloy comprises a melting point range of approximately 1,250° C. to approximately 1,650° C.

2 . The gas turbine engine component of claim 1 , wherein the at least one ceramic matrix composite material comprises an amount of residual free silicon present at approximately 0 percent by weight to approximately 4 percent by weight based on the weight of the ceramic matrix composite material.

3 . The gas turbine engine component of claim 1 , wherein either the eutectic alloy or the metal-rich alloy comprises an amount of silicon present at approximately 30 percent by weight to approximately 85 percent by weight based on the weight of either the eutectic alloy or the metal-rich alloy.

4 . The gas turbine engine component of claim 3 , wherein the eutectic alloy comprises an amount of silicon present at approximately 50 percent by weight to approximately 85 percent by weight based on the weight of the eutectic alloy.

5 . The gas turbine engine component of claim 4 , wherein the eutectic alloy comprises an amount of silicon present at approximately 50 percent by weight to approximately 60 percent by weight based on the weight of the eutectic alloy, wherein the eutectic alloy further comprises hafnium.

6 . The gas turbine engine component of claim 4 , wherein the eutectic alloy comprises an amount of silicon present at approximately 75 percent by weight to approximately 85 percent by weight based on the weight of the eutectic alloy, wherein the eutectic alloy further comprises zirconium.

7 . The gas turbine engine component of claim 3 , wherein the metal-rich alloy comprises an amount of silicon present at approximately 30 percent by weight to approximately 80 percent by weight based on the weight of the metal-rich alloy.

8 . The gas turbine engine component of claim 7 , wherein the metal-rich alloy comprises an amount of silicon present at approximately 35 percent by weight to approximately 45 percent by weight based on the weight of the metal-rich alloy, wherein the metal-rich alloy further comprises hafnium.

9 . The gas turbine engine component of claim 7 , wherein the metal-rich alloy comprises an amount of silicon present at approximately 68 percent by weight to approximately 75 percent by weight based on the weight of the metal-rich alloy, wherein the metal-rich alloy further comprises zirconium.

10 . A ceramic matrix composite material, comprising:
at least one ceramic matrix composite material, the at least one ceramic matrix composite material comprising:
a ceramic fiber reinforcement comprising at least one ceramic fiber or at least one ceramic fiber tow; and
a matrix material disposed around and in contact with the at least one ceramic fiber or the at least one ceramic fiber tow;
wherein the matrix material comprises at least one eutectic alloy, at least one metal-rich alloy, or combinations thereof;
wherein either the at least one eutectic alloy or the at least one metal-rich alloy comprises silicon and at least one of the following alloy constituents: zirconium, hafnium, tungsten, tantalum, molybdenum, niobium, and iridium;
wherein either the at least one eutectic alloy or the at least one metal-rich alloy comprises a melting point range of approximately 1,250° C. to approximately 1,650° C.

11 . The ceramic matrix composite material of claim 10 , wherein the at least one ceramic matrix composite material comprises an amount of residual free silicon present at approximately 0 percent by weight to approximately 4 percent by weight based on the weight of the at least one ceramic matrix composite material.

12 . The ceramic matrix composite material of claim 10 , wherein either the at least one eutectic alloy or the at least one metal-rich alloy comprises an amount of silicon present at approximately 30 percent by weight to approximately 85 percent by weight based on the weight of either the at least one eutectic alloy or the at least one metal-rich alloy.

13 . The ceramic matrix composite material of claim 12 , wherein the at least one eutectic alloy comprises an amount of silicon present at approximately 50 percent by weight to approximately 85 percent by weight based on the weight of the at least one eutectic alloy.

14 . The ceramic matrix composite material of claim 13 , wherein the at least one eutectic alloy comprises an amount of silicon present at approximately 50 percent by weight to approximately 60 percent by weight based on the weight of the at least one eutectic alloy, wherein the at least one eutectic alloy further comprises hafnium.

15 . The ceramic matrix composite material of claim 13 , wherein the at least one eutectic alloy comprises an amount of silicon present at approximately 75 percent by weight to approximately 85 percent by weight based on the weight of the at least one eutectic alloy, wherein the at least one eutectic alloy further comprises zirconium.

16 . The ceramic matrix composite material of claim 12 , wherein the at least one metal-rich alloy comprises an amount of silicon present at approximately 30 percent by weight to approximately 80 percent by weight based on the weight of the at least one metal-rich alloy.

17 . The ceramic matrix composite material of claim 16 , wherein the at least one metal-rich alloy comprises an amount of silicon present at approximately 35 percent by weight to approximately 45 percent by weight based on the weight of the metal-rich alloy, wherein the at least one metal-rich alloy further comprises hafnium.

18 . The ceramic matrix composite material of claim 16 , wherein the at least one metal-rich alloy comprises an amount of silicon present at approximately 68 percent by weight to approximately 75 percent by weight based on the weight of the at least one metal-rich alloy, wherein the at least one metal-rich alloy further comprises zirconium.

19 . A method of fabricating the ceramic matrix composite material according to claim 10 , comprising:
infiltrating at least one eutectic alloy constituent, at least one metal-rich alloy constituent, or combinations thereof, into, around and in contact with at least one ceramic fiber reinforcement comprising at least one ceramic fiber or at least one ceramic fiber tow, and a carbon source material; reacting either the at least one eutectic alloy constituent or the at least one metal-rich alloy constituent with the carbon source material; forming at least one matrix material within, around and in contact with the at least one ceramic fiber or the at least one ceramic fiber tow, the at least one matrix material comprising at least one eutectic alloy, at least one metal-rich alloy, and combinations thereof; and optionally further comprising at least one silicide, at least one carbide, resi

Assignees

• Rtx Corp

Inventors

• Smith Kenneth
• Srinivasan Gajawalli
• Hejazi Vahid
• Holowczak John
• Sudre Olivier H
• Mastrobattisto Daniel

Classifications

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title

• F01D25/005

  Selecting particular materials · CPC title

• C22C49/14

  characterised by the fibres or filaments · CPC title

• C22C49/02

  characterised by the matrix material · CPC title

• C22C47/10

  Infiltration in the presence of a reactive atmosphere; Reactive infiltration · CPC title