Formation of voids within components formed from porous substrates

Patent metadata

Field	Value
Publication number	US-9624138-B2
Application number	US-201514639251-A
Country	US
Kind code	B2
Filing date	Mar 5, 2015
Priority date	Apr 8, 2014
Publication date	Apr 18, 2017
Grant date	Apr 18, 2017

Abstract

A method of creating a component comprises forming a substrate and depositing a template material within the substrate, such that there are a plurality of template member. The component is heated to a temperature above a melting point of the template material, such that the template material wicks into a porosity of the substrate and forms a component with voids. An average hydraulic diameter of the voids is less than 1 millimeter. A component formed by the method, and the component itself are also disclosed.

First claim

The invention claimed is:

1. A component formed by a method comprising:
forming a substrate and depositing a template material within said substrate, such that there are a plurality of template members; and
heating said component to a temperature above a melting point of said template material, such that said template material wicks into a porosity of said substrate and forms a component with voids, wherein an average hydraulic diameter of said voids is less than 1 millimeter;
wherein a shell of silicon is formed around said voids to insulate, at least in part, the matrix material.

2. The component as set forth in claim 1 , wherein said template material is silicon.

3. The component as set forth in claim 1 , wherein said component is for use in a gas turbine engine.

4. The component as set forth in claim 1 , wherein the average hydraulic diameter of said voids is less than 100 microns.

5. The component as set forth in claim 4 , wherein said average hydraulic diameter is greater than or equal to about 10 and less than or equal to about 20 microns.

6. The component as set forth in claim 1 , wherein said substrate material initially includes graphite and said template material is silicon, such that said matrix includes a silicon carbide material.

7. The component as set forth in claim 1 , wherein said voids are utilized to receive a material subsequent to the formation of the voids.

8. The component as set forth in claim 7 , wherein said voids are subsequently filled.

9. The component as set forth in claim 1 , wherein said template material is one of fibers, particles, thin films, or sheets.

10. A component comprising:
a body formed of a matrix material and having a plurality of voids with an average hydraulic diameter of said voids being less than 1 millimeter, wherein said matrix includes a substrate material infiltrated by a silicon template material, said substrate material is further provided with metallic particles selected from a group of molybdenum, titanium, vanadium, chromium, cobalt, nickel, zirconium, niobium, hafnium, tantalum, tungsten, platinum, yttrium and boron, and said component includes a metal silicide reaction product of said metallic particles and said silicon template material.

11. The component as set forth in claim 10 , wherein said silicon template material wicks into the substrate material to form the voids at a high melt temperature.

12. The component as set forth in claim 11 , wherein said component is for use in a gas turbine engine.

13. The component as set forth in claim 11 , wherein the average hydraulic diameter of said voids is less than 100 microns.

14. The component as set forth in claim 13 , wherein said average hydraulic diameter is greater than or equal to about 10 and less than or equal to about 20 microns.

15. The component as set forth in claim 11 , wherein a shell of silicon is formed around said voids to insulate, at least in part, the matrix material.

16. The component as set forth in claim 11 , wherein said substrate material initially includes a graphite, such that said matrix includes a silicon carbide material.

17. The component as set forth in claim 11 , wherein said substrate material initially includes a carbon rich polymer derived ceramic matrix, such that said matrix is a silicon carbide matrix.

18. The component as set forth in claim 10 , wherein said reaction product comprises metal silicide regions corresponding to the metallic particles.

19. The component as set forth in claim 10 , wherein said voids are filled.

20. A component formed by a method comprising:
forming a substrate and depositing a template material within said substrate, such that there are a plurality of template members; and
heating said component to a temperature above a melting point of said template material, such that said template material wicks into a porosity of said substrate and forms a component with voids, wherein an average hydraulic diameter of said voids is less than 1 millimeter;
wherein said substrate material initially includes a carbon rich polymer derived ceramic matrix and said template material is silicon, such that said component includes a silicon carbide matrix, and wherein said substrate material is further provided with metallic particles, selected from the group of molybdenum, titanium, vanadium, chromium, cobalt, nickel, zirconium, niobium, hafnium, tantalum, tungsten, platinum, yttrium and boron, such that said component also includes corresponding metal silicide regions.

Assignees

• United Technologies Corp

Inventors

• Sheedy Paul
• Schmidt Wayde R

Classifications

• C04B38/061

  by melting out · CPC title

• C04B35/573

  obtained by reaction sintering {or recrystallisation} · CPC title

• C04B2235/40

  Metallic constituents or additives not added as binding phase · CPC title

• C04B2235/6028

  Shaping around a core which is removed later · CPC title

• C04B2235/614

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