Ceramic material having ceramic matrix composite backing and method of manufacturing

• US 20040110041A1
• Filed: 09/04/2003
• Published: 06/10/2004
• Est. Priority Date: 09/06/2002
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Power Generation, Inc.
• Inventors: Morrison, Jay A., Hoffmann, Stefan, Merrill, Gary B., Hofmann, Daniel, Tertilt, Marc, Thompson, Daniel G., Burke, Michael A.
• Granted Patent: US 7,291,407 B2
• Time in Patent Office: Days
• US Class Current: 428/699
• CPC Class Codes: B32B 2315/02 Ceramics
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
• CPC Class Codes: C04B 2235/5228 Silica and alumina, including aluminosilicates, e.g. mullite
• CPC Class Codes: C04B 2235/94 Products characterised by their shape
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 2237/062 based on silica or silicates
• CPC Class Codes: C04B 2237/064 based on alumina or aluminates
• CPC Class Codes: C04B 2237/10 Glass interlayers, e.g. frit or flux
• CPC Class Codes: C04B 2237/38 Fiber or whisker reinforced
• CPC Class Codes: C04B 35/10 based on aluminium oxide
• CPC Class Codes: C04B 35/185 Mullite 3Al2O3-2SiO2
• CPC Class Codes: C04B 35/6316 Binders based on silicon compounds
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 37/005 consisting of glass or ceramic material
• CPC Class Codes: F23M 2900/05004 Special materials for walls or lining
• CPC Class Codes: F23R 3/007 constructed mainly of ceramic components
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

An article comprising a ceramic material having a ceramic matrix composite backing adapted for use in a gas turbine engine is provided. The article comprises a structural ceramic material having a hot side facing toward a high temperature environment and a cold side facing away from the high temperature environment; and a ceramic matrix composite composition having a strength greater than the strength of the ceramic material attached to the back of the cold side of the ceramic material, whereby crack initiation and propagation are inhibited by the ceramic matrix composition to a greater degree than by the ceramic material.

Claims

1. An article of manufacture, comprising:

a structural ceramic material having a hot side facing toward a high temperature environment and a cold side facing away from the high temperature environment; and

a ceramic matrix composite composition having a strength greater than the strength of the ceramic material attached to the back of the cold side of the ceramic material,

whereby crack initiation and propagation are inhibited by the ceramic matrix composite to a greater degree than by the ceramic material.

2. The article of claim 1, wherein the ceramic material comprises a binary oxide material.

3. The article of claim 2, wherein the ceramic material is selected from the group consisting of:

alumina, silica and zirconia.

4. The article of claim 1, wherein the ceramic material is shaped to form a tile.

5. The article of claim 1, wherein the ceramic matrix composite comprises a ceramic fiber reinforced ceramic matrix material.

6. The article of claim 4, wherein the ceramic fiber comprises alumnosilicate particles.

7. The article of claim 4, wherein the ceramic matrix material comprises bonded alumina or mullite particles.

8. A component of a gas turbine engine, comprising:

a structural ceramic material having a hot side facing toward a high temperature environment and a cold side facing away from the high temperature environment;

a ceramic matrix composite backing having a strength greater than the strength of the ceramic material; and

an adhesive arranged between the ceramic material and the ceramic matrix composite adapted to bond the back of the cold side of the ceramic material to the ceramic matrix composite,

whereby crack initiation and propagation are inhibited by the ceramic matrix composite to a greater degree than by the ceramic material.

9. The article of claim 8, wherein the component is a combustion liner.

10. The article of claim 8, wherein the adhesive comprises a ceramic powder and a liquid binder.

11. The article of claim 10, wherein the liquid binder comprises silica sol or an oxychloride solution.

12. The article of claim 8, wherein the adhesive comprises a glass frit.

13. The article of claim 8, wherein one adhesive is applied onto the entire cold side of the ceramic material.

15. The combustion liner of claim 13, wherein the green ceramic matrix composition is applied by cutting fibers of the ceramic matrix composite and then applying the cut fibers to the tile surface and then infiltrating the matrix material around the fibers.

16. The combustion liner of claim 13, wherein the green ceramic matrix composition is applied by cutting a number of fabric plies of ceramic matrix composite material to the surface profile of the tile and then stacking the plies onto the backside of the tile.

17. The combustion liner of claim 13, wherein the plies of ceramic matrix composite material are oriented at an angle of about 45°

relative to the major axis of the ceramic tile 12.

18. The combustion liner of claim 13, wherein the stacked plies are subsequently vacuum bagged or otherwise compressed to compact the plies to a desired thickness.

19. The combustion liner of claim 13, wherein the bond strength between the ceramic material and the ceramic matrix composite composition is up to 6.2 Mpa.

20. The method of claim 13, wherein the ceramic matrix composite composition is arranged on an edge of the ceramic material.

14. A method of manufacturing a combustion liner tile adapted for use in a combustion turbine engine, comprising:

providing a structural ceramic material having a hot side facing toward a high temperature environment and a cold side facing away from the high temperature environment;

applying a layer of green ceramic matrix composite composition onto the structural ceramic material; and

heating the ceramic matrix composite composition and the ceramic material to a temperature in excess of about 1100°

C. to form the combustion liner tile having a strength greater than the strength of the ceramic material.