Double transition joint for the joining of ceramics to metals

Patent metadata

Field	Value
Publication number	US-9011620-B2
Application number	US-55838709-A
Country	US
Kind code	B2
Filing date	Sep 11, 2009
Priority date	Sep 11, 2009
Publication date	Apr 21, 2015
Grant date	Apr 21, 2015

Abstract

The invention is directed to effective means for joining materials having dissimilar coefficients of thermal expansion, such as advanced ceramics with metallic compounds. Moreover, the present invention relates to furnace tubes and methods of fabricating a joint between two different materials, which is compositionally graded to provide a substantially graded coefficient of thermal expansion between the joint materials.

First claim

What is claimed is:

1. A method of fabricating a joint between two materials in an apparatus comprising transitioning from a first material A to a first metal material B wherein first material A and first metal material B are chemically and thermomechanically incompatible at a temperature of operation of said apparatus, said method comprising:
i) a first transitioning of said first material A to a second material C, wherein second material C is compatible at the temperature of operation of said apparatus with both first material A and first metal material B, said first transitioning between first material A and second material C is graded to provide a gradation starting with 100 percent first material A and having a continuous compositional change in the amount of first material A and second material C until there is 100 percent of second material C having a coefficient of thermal expansion which substantially grades between the first material A and second material C; and
ii) a second transitioning of said second material C to the first metal material B, said second transitioning between the second material C and first metal material B is graded to provide a gradation starting with 100 percent second material C and having a continuous compositional change in the amount of second material C and first metal material B until there is 100 percent of first metal material B having a coefficient of thermal expansion which substantially grades between the second material C and the first metal material B, wherein first material A is silicon carbide based, first metal material B is iron chromium nickel based, and second material C is alumina and the proviso that said joint contains at least two gradations.

2. The method of claim 1 wherein first metal material B is more than one metal material.

3. The method of claim 1 wherein said first and second transitioning is performed by at least one process selected from the group consisting of conventional powder processing and firing, bulk particulate processing, pre-form processing, layer processing, melt infiltration techniques, extrusion and thermal spraying, diffusion bonding, thermal spraying, thermal extrusion, and diffusion bond brazing.

4. The method of claim 3 wherein said first and second transitioning further comprises an additional metal material.

5. The method of claim 1 wherein the second transitioning between the second material C and the first metal material B further comprises an additional metal material.

6. The method of claim 5 wherein the additional metal material is at least one selected from the group consisting of iron-, nickel-, titanium- cobalt-, and palladium-based materials and alloys.

7. The method of claim 1 further comprising a third transitioning between said first metal material B and a third material D wherein the third transitioning between said first metal material B and said third material D is graded to provide a gradation having a substantially graded composition and/or coefficient of thermal expansion between said first metal material B and said third material D.

8. The method of claim 1 wherein second material C has a coefficient of thermal expansion that is intermediate to the coefficient of thermal expansion of first material A and first metal material B.

9. The method of claim 1 , wherein said first and second transitioning steps utilize solid-state diffusion bonding.

10. The method of claim 1 wherein second material C has a coefficient of thermal expansion that is intermediate to the coefficient of thermal expansion of first material A and first metal material B.

11. A method of fabricating a joint between two materials in an apparatus comprising transitioning from a first material A to a first metal material B wherein first material A and first metal material B are chemically and thermomechanically incompatible at a temperature of operation of said apparatus, said method comprising:
i) a first transitioning of said first material A that is at least one material selected from the group consisting of SiC, B 4 C, WC, BN, Si 3 N 4 , SiAlON, TiB 2 , ZrB 2 , and MgB 2 to a second material C that is at least one material selected from the group consisting of alumina, zirconia, and spinel, wherein second material C is compatible at the temperature of operation of said apparatus with both first material A and first metal material B, said transitioning between first material A and second material C is graded to provide a gradation starting with 100 percent first material A and having a continuous compositional change in the amount of first material A and second material C until there is 100 percent of second material C having a coefficient of thermal expansion which substantially grades between the first material A and second material C; and
ii) a second transitioning of said second material C to the first metal material B that is at least one metal material selected from the group consisting of alloys of aluminum, alloys of copper, alloys of magnesium, alloys of zinc, alloys of iron, alloys of nickel, and alloys of titanium, wherein said second transitioning between the second material C and first metal material B is graded to provide a gradation starting with 100 percent second material C and having a continuous compositional change in the amount of second material C and first metal material B until there is 100 percent of first metal material B having a coefficient of thermal expansion which substantially grades between the second material C and the first metal material B, with the proviso that said joint contains at least two gradations.

12. The method of claim 11 , wherein said first and second transitioning steps utilize solid-state diffusion bonding.

13. The method of claim 11 , wherein first metal material B is more than one metal material.

14. The method of claim 11 , wherein said first and second transitioning is performed by at least one process selected from the group consisting of conventional powder processing and firing, bulk particulate processing, pre-form processing, layer processing, melt infiltration techniques, extrusion and thermal spraying, diffusion bonding, thermal spraying, thermal extrusion, and diffusion bond brazing.

15. The method of claim 11 , wherein said first and second transitioning further comprises an additional metal material.

16. The method of claim 11 , wherein the second transitioning between the second material C and the first metal material B further comprises an additional metal material.

17. The method of claim 16 , wherein the additional metal material is at least one selected from the group consisting of titanium- cobalt-, and palladium-based materials and alloys.

Assignees

• Fernie John Andrew
• Roberts Martyn David
• Wang Yong
• Kavilveedu Narayanan Rajesh
• Brown David J
• Technip Process Technology Inc

Inventors

• Fernie John Andrew
• Roberts Martyn David
• Wang Yong
• Kavilveedu Narayanan Rajesh
• Brown David J

Classifications

• C04B2235/3826

  Silicon carbides · CPC title

• C04B2237/122

  based on refractory metals · CPC title

• C04B2237/403

  Refractory metals · CPC title

• C04B2237/062

  based on silica or silicates · CPC title

• C04B2237/407

  Copper · CPC title