METHODS OF PREPARING WETTING-RESISTANT SURFACES AND ARTICLES INCORPORATING THE SAME

• US 20080145528A1
• Filed: 12/14/2006
• Published: 06/19/2008
• Est. Priority Date: 12/14/2006
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Subramanian, Pazhayannur Ramanathan, Deng, Tao, Bhate, Nitin, Lau, Yuk-Chiu, Hsu, Ming Feng, Varanasi, Kripa Kiran, Blohm, Margaret L., O'Neil, Gregory Allen, Hasz, Wayne Charles
• Granted Patent: US 7,919,151 B2
• Time in Patent Office: Days
• US Class Current: 427/180
• CPC Class Codes: B05D 1/60 Deposition of organic layers from vapour phase vapour phase deposition in general C23C14/00, C23C16/00
• CPC Class Codes: B05D 5/083 involving the use of fluoropolymers
• CPC Class Codes: C23C 24/08 by application of heat or pressure and heat C23C24/04 takes precedence
• CPC Class Codes: C23C 24/10 with intermediate formation of a liquid phase in the layer

Abstract

The present invention provides methods for manufacturing an article having a wetting-resistant surface. The method includes providing a substrate. The method further includes disposing a coating mixture on a surface of the substrate, wherein the coating mixture comprises a braze material and a texture-providing material. The method further includes heating the braze material to bond the texture-providing material to the surface of the substrate to form the article having the wetting-resistant surface.

Claims

1. A method for manufacturing an article having a wetting-resistant surface comprising:

providing a substrate;

disposing a coating mixture on a surface of the substrate, wherein the coating mixture comprises a braze material and a texture-providing material; and

heating the braze material to bond the texture-providing material to the surface of the substrate to form the article having the wetting-resistant surface, wherein the wetting-resistant surface has a surface area enhancement of greater than about 1.2.

2. The method of claim 1, wherein the substrate comprises a ceramic or a metal.

3. The method of claim 1, wherein the article comprises a component of an aircraft.

4. The method of claim 1, wherein the article comprises a component of a turbine assembly.

5. The method of claim 1, wherein the coating mixture is substantially free of flux.

6. The method of claim 1, wherein the braze material comprises a nickel-based alloy, a cobalt-based alloy, an iron-based alloy, an aluminum-based alloy, a titanium-based alloy or a copper-based alloy.

7. The method of claim 1, wherein the texture-providing material comprises a plurality of particles having a median size of less than about 1000 micrometers in at least one dimension.

8. The method of claim 1, wherein the texture-providing material comprises a plurality of particles having a median size in the range from about 1 micrometer to about 250 micrometers in at least one dimension.

9. The method of claim 1, wherein the texture-providing material comprises a plurality of particles having a median size of less than about 1 micrometer in at least one dimension.

10. The method of claim 1, wherein the texture-providing material comprises a plurality of particles having a median aspect ratio of greater than about 1.

11. The method of claim 1, wherein the texture-providing material comprises a plurality of particles having a median aspect ratio of greater than about 10.

12. The method of claim 1, wherein the texture-providing material comprises a plurality of particles comprising a nanotube or a nanorod.

13. The method of claim 12, wherein the nanotube comprises a carbon nanotube.

14. The method of claim 1, wherein the texture-providing material comprises ceramic particles.

15. The method of claim 14, wherein the ceramic particles comprise an oxide, a mixed oxide, a nitride, a boride or a carbide.

16. The method of claim 14, wherein the texture-providing material comprises boron nitride.

17. The method of claim 1, wherein the texture-providing material comprises metallic particles.

18. The method of claim 1, wherein the texture-providing material comprises intermetallic particles.

19. The method of claim 18, wherein the intermetallic particles comprise a silicide, an aluminide or any combinations thereof.

20. The method of claim 1, wherein the texture-providing material comprises a material having an inherent contact angle that is greater than about 90 degrees.

21. The method of claim 20, wherein the texture-providing material comprises a material having an inherent contact angle that is greater than about 100 degrees.

22. The method of claim 1, wherein the texture-providing material comprises particles comprising surface features disposed on their surfaces, wherein the surface features have a median size of less than about 10 micrometers.

23. The method of claim 1, wherein disposing the coating mixture on the surface of the substrate comprises:

providing a first coating comprising a braze material on the surface of the substrate; and

disposing a second coating comprising the texture-providing material on the first coating.

24. The method of claim 1, wherein disposing the coating mixture on the surface of the substrate comprises:

providing a first bonding layer comprising an adhesive on the surface of the substrate;

disposing the braze material on the first bonding layer;

providing a second bonding layer comprising an adhesive on the braze material; and

disposing the texture-providing material on the second bonding layer.

25. The method of claim 1, wherein heating the braze material to bond the texture-providing material to the surface comprises providing a temperature greater than about 450 degrees Celsius so as to melt the braze material.

26. The method of claim 1, wherein the wetting-resistant surface has a contact angle with water greater than about 90 degrees.

27. The method of claim 1, wherein a particle density of the texture-providing material on the wetting-resistant surface is greater than about 10⁵ particles/cm².

28. The method of claim 27, wherein the particle density of the texture-providing material on the wetting-resistant surface is in the range from about 10⁵ particles/cm² to about 10¹⁵ particles/cm².

29. The method of claim 1, wherein the texture-providing material comprises a plurality of particles having a multimodal size distribution.

30. The method of claim 1, further comprising modifying the wetting-resistant surface by applying a top coat comprising diamond-like carbon, titanium oxide, tantalum oxide, titanium nitride, titanium carbo-nitride, chromium nitride, chromium carbide, boron nitride, zirconium nitride, titanium carbide, tungsten carbide, molybdenum carbide, molybdenum boride or tungsten boride.

31. An article fabricated using the method of claim 1.

32. A method for manufacturing an article having a wetting-resistant surface comprising:

providing a substrate;

disposing a coating mixture on a surface of the substrate, the coating mixture comprising a braze material and a texture-providing material, wherein the texture-providing material comprises a plurality of particles having a median size of less than about 1 micrometer in at least one dimension; and

heating the braze material to bond the texture-providing material to the surface of the substrate to form the article having the wetting-resistant surface.

33. The method of claim 32, wherein the coating mixture is substantially free of flux.

34. The method of claim 32, wherein the plurality of particles has a median aspect ratio of greater than about 1.

35. The method of claim 32, wherein the plurality of particles comprises a nanotube or a nanorod.

36. The method of claim 32, wherein a particle density of the texture-providing material on the wetting-resistant surface is greater than about 10⁵ particles/cm².

37. The method of claim 32, wherein the texture-providing material comprises particles comprising surface features disposed on their surfaces.

38. The method of claim 32, further comprising modifying the wetting-resistant surface by applying a top coat comprising a diamond-like carbon, titanium oxide, tantalum oxide, titanium nitride, titanium carbo-nitride, chromium nitride, chromium carbide, boron nitride, zirconium nitride, titanium carbide, tungsten carbide, molybdenum carbide, molybdenum boride or tungsten boride.

39. The method of claim 32, wherein the wetting-resistant surface has a contact angle with water greater than about 90 degrees.

40. An article fabricated using the method of claim 32.

41. A method for manufacturing an article having a wetting-resistant surface comprising:

providing a substrate;

disposing a coating mixture on a surface of the substrate, wherein the coating mixture comprises a braze material and a texture-providing material, wherein the texture-providing material comprises a plurality of particles having surface features disposed on a surface of the plurality of particles; and

heating the braze material to bond the texture-providing material to the surface of the substrate to form the article having the wetting-resistant surface.

42. The method of claim 41, wherein the coating mixture is substantially free of flux.

43. The method of claim 41, wherein the braze material comprises a nickel-based alloy, a cobalt-based alloy, an iron-based alloy, an aluminum-based alloy, a titanium-based alloy or a copper-based alloy.

44. The method of claim 41, wherein the texture-providing material comprises ceramic particles.

45. The method of claim 44, wherein the ceramic particles comprise an oxide, a mixed oxide, a nitride, a boride or a carbide.

46. The method of claim 41, wherein the texture-providing material comprises metallic particles.

47. The method of claim 41, wherein the texture-providing material comprises intermetallic particles.

48. The method of claim 41, wherein the texture-providing material comprises a material having an inherent contact angle that is greater than about 90 degrees.

49. The method of claim 41, wherein the surface features have a median size of less than about 10 micrometers.

50. The method of claim 41, wherein the wetting-resistant surface has a contact angle with water greater than about 90 degrees.

51. The method of claim 41, wherein a particle density of the texture-providing material on the wetting-resistant surface is greater than about 10⁵ particles/cm².

52. The method of claim 41, further comprising modifying the wetting-resistant surface by applying a top coat comprising diamond-like carbon, titanium oxide, tantalum oxide, titanium nitride, titanium carbo-nitride, chromium nitride, chromium carbide, boron nitride, zirconium nitride, titanium carbide, tungsten carbide, molybdenum carbide, molybdenum boride or tungsten boride.

53. An article fabricated using the method of claim 41.

54. An article comprising:

a substrate; and

a coating disposed on a surface of the substrate to form a wetting-resistant surface, wherein the coating comprises a texture-providing material, wherein the texture-providing material is bonded to the surface of the substrate by a braze material and wherein the wetting-resistant surface has a surface area enhancement of greater than about 1.2.

55. The article of claim 54, wherein the texture-providing material comprises a plurality of particles having a median size of less than about 1000 micrometers in at least one dimension.

56. The article of claim 54, wherein the texture-providing material comprises a plurality of particles having a median aspect ratio of greater than about 10.

57. The article of claim 54, wherein the texture-providing material comprises particles comprising surface features disposed on their surfaces, wherein the surface features have a median size of less than about 10 micrometers.

58. The article of claim 54, further comprising a base component, wherein the substrate is attached to the base component.

59. The article of claim 54, wherein the article comprises a component of an aircraft.

60. The article of claim 59, wherein the component comprises at least one selected from the group consisting of a fuselage, a wing, a tail, and an aircraft engine component.

61. The article of claim 60, wherein the aircraft engine component is at least one selected from the group consisting of a nacelle lip, a splitter leading edge, a booster inlet guide vane, a fan outlet guide vane, a fan blade, a turbine blade, a turbine vane, a sensor, and a sensor shield.

62. The article of claim 54, wherein the article comprises a component of a turbine assembly.

63. The article of claim 62, wherein the turbine assembly is selected from the group consisting of a wind turbine assembly, a gas turbine assembly, and a steam turbine assembly.

64. The article of claim 63, wherein the wind turbine assembly comprises at least one component selected from the group consisting of a turbine blade, an anemometer, and a gearbox.

65. The article of claim 62, wherein the component of the turbine assembly is at least one selected from the group consisting of a turbine blade, a low-pressure steam turbine blade, a high-pressure steam turbine blade, a compressor blade, a condenser, and a stator component.

66. The article of claim 54, wherein the wetting-resistant surface has a contact angle with water greater than about 90 degrees.