Aligned composite structures for mitigation of impact damage and resistance to wear in dynamic environments

• US 20060091580A1
• Filed: 12/09/2005
• Published: 05/04/2006
• Est. Priority Date: 12/04/2000
• Status: Active Grant

• Current Assignee: Advanced Ceramics Research LLC
• Original Assignee: Advanced Ceramics Research, Inc. (Rtx Corporation)
• Inventors: Popovich, Dragan, Rigali, Mark J., Fulcher, Michael L., Mulligan, Anthony C., Sutaria, Manish P., Cook, Randy C., Halloran, Joseph P.
• Granted Patent: US 7,517,580 B2
• Time in Patent Office: Days
• US Class Current: 264/172.15
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 2315/02 Ceramics
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: C04B 2235/3843 Titanium carbides
• CPC Class Codes: C04B 2235/524 Non-oxidic, e.g. borides, carbides, silicides or nitrides
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 2235/6567 Treatment time
• CPC Class Codes: C04B 2235/658 Atmosphere during thermal treatment
• CPC Class Codes: C04B 2237/34 Oxidic
• CPC Class Codes: C04B 2237/341 Silica or silicates
• CPC Class Codes: C04B 2237/343 Alumina or aluminates
• CPC Class Codes: C04B 2237/363 Carbon
• CPC Class Codes: C04B 2237/368 Silicon nitride
• CPC Class Codes: C04B 2237/38 Fiber or whisker reinforced
• CPC Class Codes: C04B 2237/704 of one or more of the ceramic layers or articles
• CPC Class Codes: C04B 2237/76 Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
• CPC Class Codes: C04B 35/117 Composites
• CPC Class Codes: C04B 35/62865 Nitrides
• CPC Class Codes: C04B 35/62868 Boron nitride
• CPC Class Codes: C04B 35/645 : Pressure sintering
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C08K 3/34 : Silicon-containing compounds
• CPC Class Codes: C08K 7/04 : inorganic
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/24926 : including ceramic, glass, porcelain or quartz layer
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249964 : Fibers of defined composition
• CPC Class Codes: Y10T 428/249965 : Cellulosic
• CPC Class Codes: Y10T 428/24998 : Composite has more than two layers
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 442/2615 : Coating or impregnation is resistant to penetration by solid implements
• CPC Class Codes: Y10T 442/2623 : Ballistic resistant

Abstract

Fibrous monolith composites having architectures that provide increased flaw insensitivity, improved hardness, wear resistance and damage tolerance and methods of manufacture thereof are provided for use in dynamic environments to mitigate impact damage and increase wear resistance.

Claims

1. A method of preparing a fibrous monolith composite comprising:

providing one or more green fibrous monolith filaments having a core composition and a shell composition that differs from the core composition;

arranging the one or more filaments in a predetermined orientation to form a first layer;

providing one or more additional green fibrous monolith filaments having a core composition and a shell composition that differs from the core composition;

arranging the one or more additional filaments in a second predetermined orientation to form a second layer, wherein the second layer is disposed adjacent the first layer; and

shaping the layers to form the composite.

2. The method of claim 1 wherein the composite is disposed on a wear surface of a substrate and compression forces are applied to the composite and substrate.

3. The method of claim 2 further comprising adhering the composite to a wear surface with an adhesive compound.

4. The method of claim 1 wherein at least a portion of the filaments extend in a direction normal to the wear surface.

5. The method of claim 1 wherein a coating portion is formed from the green fibrous monolith filaments, the coating portion having a shape generally corresponding to the shape of the area of the wear surface to which it is to be applied to limit further shaping of the coating portion upon application to the wear surface.

6. The method of claim 5 wherein coating portion is formed by arranging one or more green fibrous monolith filaments in a die having an elongated, annular cavity to provide an annular feed rod upon application of compression forces, and

sectioning the feed rod lengthwise along the longitudinal axis and sectioning the feed rod transversely into portions of a predetermined thickness to form a plurality of coating portions;

wherein each of the coating portions is applied about the outer surface of a substrate having a generally conical configuration to provide a wear part with integral coating upon application of heat and compression forces.