Method for protecting a hybrid ceramic structure from moisture attack in a high temperature environment

• US 10,112,875 B2
• Filed: 03/31/2016
• Issued: 10/30/2018
• Est. Priority Date: 07/22/2008
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Energy Incorporated (Siemens AG)
• Inventors: Lane, Jay E., Merrill, Gary B.
• Primary Examiner(s): Snelting, Erin
• Application Number:
  US15/087,324
• Publication Number:
  US 20160207841A1
• Time in Patent Office: 943 Days
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: C04B 28/34 containing cold phosphate binders
• CPC Class Codes: C04B 35/803 The matrix of the ceramic products consisting of oxides only
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4535 applied as a solution, emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/457 Non-superficial impregnation or infiltration of the substrate
• CPC Class Codes: C04B 41/5024 Silicates C04B41/5022 takes precedence; silico-fluorides C04B41/5018
• CPC Class Codes: C04B 41/5025 with ceramic materials copper oxide or solid solutions thereof C04B41/5074
• CPC Class Codes: C04B 41/5032 Aluminates aluminate spinels C04B41/5046
• CPC Class Codes: C04B 41/5042 Zirconium oxides or zirconates; Hafnium oxides or hafnates
• CPC Class Codes: C04B 41/5044 Hafnates
• CPC Class Codes: C04B 41/5045 Rare-earth oxides
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

A method for protecting the hybrid ceramic structure from moisture attack in a high temperature combustion environment is provided. The structure includes a ceramic matrix composite (CMC) substrate (12). A thermal insulation material (14) is disposed on the substrate. A vapor resistant material (20) is applied through at least one surface of the hybrid ceramic structure while the hybrid ceramic structure is in a bisque condition that provides a degree of porosity to the hybrid ceramic structure so that the vapor resistant material is infiltrated through interstices available within a thickness of the hybrid ceramic structure.

Claims

1. A method for protecting a hybrid ceramic structure from moisture attack in a high temperature combustion environment containing moisture, the hybrid ceramic structure comprising a ceramic matrix composite substrate and a thermal insulation material disposed on the substrate, the method comprising:

processing the hybrid ceramic structure to be in a bisque condition that provides a degree of porosity to the hybrid ceramic structure;

applying a vapor resistant material through surfaces of the thermal insulation material and the ceramic matrix composite substrate while the hybrid ceramic structure is in the bisque condition;

as a result of the degree of porosity provided by the bisque condition, infiltrating the vapor resistant material through interstices available within a thickness of the hybrid ceramic structure; and

sintering the hybrid ceramic structure to a fully sintered condition.

2. The method of claim 1, wherein the applying of the vapor resistant material comprises applying the vapor resistant material when the hybrid ceramic structure is in a temperature range from 500°

C. to 1350°

C.

3. The method of claim 1, wherein the infiltrating of the vapor resistant material comprises partially filling at least some of the interstices available within the thickness of the hybrid ceramic structure.

4. The method of claim 1, wherein the infiltrating of the vapor resistant material comprises filling at least some of the interstices available within the thickness of the hybrid ceramic structure.

5. The method of claim 1, wherein the infiltrating of the vapor resistant material comprises infiltrating into a binder material of the thermal insulation material where a plurality of geometric shapes is packed, the infiltrating into the binder material incrementing a densification level of a body formed by the binder material.