Method for incorporating refractory metal element into ceramic matrix composite

Patent metadata

Field	Value
Publication number	US-9593049-B2
Application number	US-201615049712-A
Country	US
Kind code	B2
Filing date	Feb 22, 2016
Priority date	Feb 20, 2015
Publication date	Mar 14, 2017
Grant date	Mar 14, 2017

Abstract

A method of forming a ceramic matrix composite are described herein. The method may include infiltrating a fiber preform with a solution comprising a refractory precursor in solution with a solvent. The refractory precursor may include a compound having at least one refractory metal element. The method may further include removing the solvent from the fiber preform, and reducing the refractory precursor to form a refractory metal that includes the refractory metal element.

First claim

What is claimed is:

1. A method of forming a ceramic matrix composite comprising:
infiltrating a fiber preform with a solution comprising a refractory precursor in solution with a solvent, the refractory precursor comprising a compound having at least one refractory metal element;
removing the solvent from the fiber preform; and
reducing the refractory precursor to form a refractory metal comprising the refractory metal element.

2. The method of claim 1 , wherein the refractory metal element comprises molybdenum, tungsten or a combination thereof.

3. The method of claim 1 , further comprising melt infiltrating the fiber preform with a molten silicon containing metal or alloy to form the ceramic matrix composite.

4. The method of claim 3 , wherein at least some of the refractory metal forms a silicide as a result of the melt infiltration.

5. The method of claim 4 , wherein the silicide comprises MoSi2, WSi2 or a combination thereof.

6. The method of claim 1 , wherein the solvent comprises H 2 O.

7. The method of claim 6 , wherein the solvent further comprises H 2 O 2 or H 2 PO 4 or a combination thereof.

8. The method of claim 1 , wherein the refractory precursor dissociates in the solvent.

9. The method of claim 1 , wherein the fiber preform comprises silicon containing refractory fibers.

10. The method of claim 9 , wherein the silicon containing refractory fibers comprise silicon carbide.

11. The method of claim 1 , wherein the reducing the refractory precursor comprises:
reducing the refractory precursor to form a refractory oxide; and
reducing the refractory oxide to form the refractory metal.

12. The method of claim 1 , wherein the refractory precursor comprises (NH 4 ) 2 Mo 2 O 7 , (NH 4 ) 6 Mo 7 O 24 .4H 2 O, (NH 4 ) 2 MoO 4 , (NH 4 ) 10 (H 2 W 12 O 24 ).4H 2 O or a combination thereof.

13. The method of claim 1 , wherein the refractory metal element comprises at least 20% by weight of the solution.

14. The method of claim 1 , wherein the removing the solvent comprises heating the fiber preform.

15. The method of claim 1 , further comprising infiltrating the fiber preform with a slurry substantially without the refractory precursor prior to the infiltrating the fiber preform with the solution.

16. The method of claim 15 , wherein the infiltrated slurry restricts infiltration of the solution into an interior region of the fiber preform.

17. The method of claim 1 , wherein the solution is selectively applied to the fiber preform so that the solution infiltrates only a select region or regions of the fiber preform.

18. The method of claim 17 , wherein the solution is applied by dip coating, spray-on, brush technique or a combination thereof.

Assignees

• Rolls-Royce High Temperature Composites Inc
• Rolls Royce Corp
• Rolls-Royce High Temperature Composites Inc

Inventors

• Harris Stephen I
• Shim Sungbo
• Shinavski Robert J
• Landwehr Sean E

Classifications

• C04B2235/6582

  Hydrogen containing atmosphere · CPC title

• C04B2235/661

  Multi-step sintering · CPC title

• C04B2235/428

  Silicon · CPC title

• C04B2235/3258

  Tungsten oxides, tungstates, or oxide-forming salts thereof · CPC title

• C04B2235/77

  Density · CPC title