Carbon-carbon composite component with antioxidant coating

• US 10,302,163 B2
• Filed: 02/19/2016
• Issued: 05/28/2019
• Est. Priority Date: 05/13/2015
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Rowe, Jeffrey, Gomez, Alan, Fryska, Slawomir T.
• Primary Examiner(s): Polley, Christopher M
• Application Number:
  US15/048,840
• Publication Number:
  US 20160333955A1
• Time in Patent Office: 1,194 Days
• Field of Search: None
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29L 2031/16 Frictional elements, e.g. brake or clutch linings
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C04B 2111/00362 Friction materials, e.g. used as brake linings, anti-skid materials
• CPC Class Codes: C04B 2111/00982 as construction elements for space vehicles or aeroplanes
• CPC Class Codes: C04B 2235/6026 Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• 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 41/455 the coating or impregnating process including a chemical conversion or reaction
• CPC Class Codes: C04B 41/4572 Partial coating or impregnation of the surface of the substrate
• CPC Class Codes: C04B 41/4574 Coating different parts of the substrate with different materials
• CPC Class Codes: C04B 41/5059 Silicon carbide
• CPC Class Codes: C04B 41/5092 Phosphate cements
• CPC Class Codes: C04B 41/52 Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/89 for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: F16D 69/023 : Composite materials containing carbon and carbon fibres or fibres made of carbonizable material

Abstract

In one example, a method including depositing an antioxidant material on a first surface region of a carbon-carbon composite substrate via a print head of a three-dimensional printing device to form a first layer of the antioxidant material on the first surface region of the substrate, and depositing the antioxidant material on a second surface region of the substrate via the print head of the three-dimensional printing device to form a second layer of the antioxidant material on the second surface region. The method may be, for example, a method for forming a carbon-carbon composite component including an antioxidant coating, the antioxidant coating including the first layer and second layer of the antioxidant material.

Claims

1. A method for forming a carbon-carbon composite component including an antioxidant coating, the method comprising:

depositing an antioxidant material on a first surface region of a carbon-carbon composite substrate via a print head of a three-dimensional printing device to form a first layer of the antioxidant material on the first surface region of the substrate; and

after forming the first layer, depositing the antioxidant material on a second surface region of the substrate via the print head of the three-dimensional printing device to form a second layer of the antioxidant material on the second surface region, wherein the antioxidant material comprises at least one of a phosphorus based antioxidation compound or a ceramic precursor compound, and wherein the antioxidant coating comprises the first layer and the second layer of the antioxidant material.

2. The method of claim 1, wherein the first layer comprises a penetrant type layer of antioxidant material.

3. The method of claim 1, wherein the first layer comprises a barrier type layer of antioxidant material.

4. The method of claim 1, wherein at least a portion of the second layer overlaps a portion of the first layer.

5. The method of claim 1, wherein the antioxidant coating includes a plurality of individual layers of the antioxidant material, including the first layer and second layer, defining an overall thickness of the antioxidant coating of approximately 2 microns to approximately 30 microns.

6. The method of claim 1, wherein the first layer and the second layer each define a thickness between approximately one micron and approximately 10 microns.

7. The method of claim 1, further comprising leaving a third surface region of the substrate not covered with antioxidant material, wherein the first surface region and the second surface region of the substrate comprise non-friction surface regions of the substrate, and the third surface region of the substrate comprises a friction surface of the substrate.

8. The method of claim 1, wherein the carbon-carbon composite material exhibits a density greater than or equal to approximately 1.7 grams per cubic centimeter.

9. The method of claim 1, further comprising densifying a carbonized carbon fiber preform to form the carbon-carbon composite material prior to depositing the antioxidant material.

10. The method of claim 1, wherein the first layer is positioned between the second layer and the carbon-carbon composite substrate.

11. The method of claim 1, wherein the first layer and the second layer are directly adjacent to each other.

12. The method of claim 1, wherein the second layer is positioned directly on the first layer.

13. The method of claim 1, wherein the first surface region and the second surface region of the substrate comprise non-friction surface regions of the substrate.