COMPONENTS AND METHODS OF FORMING PROTECTIVE COATING SYSTEMS ON COMPONENTS

• US 20090297866A1
• Filed: 07/30/2007
• Published: 12/03/2009
• Est. Priority Date: 07/31/2006
• Status: Abandoned Application

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Lindberg, Laura J., DelaCruz, Christian, Raybould, Derek, Strangman, Thomas E., Chipko, Paul
• Application Number:
  US11/830,092
• Publication Number:
  US 20090297866A1
• Time in Patent Office: Days
• US Class Current: 428/446
• CPC Class Codes: C04B 2235/3206 Magnesium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3213 Strontium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3224 Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• CPC Class Codes: C04B 2235/3225 Yttrium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3232 Titanium oxides or titanates, e.g. rutile or anatase
• CPC Class Codes: C04B 2235/3244 Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3256 Molybdenum oxides, molybdates or oxide forming salts thereof, e.g. cadmium molybdate
• CPC Class Codes: C04B 2235/3279 Nickel oxides, nickalates, or oxide-forming salts thereof
• 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 35/495 based on vanadium, niobium, tantalum, molybdenum or tungsten oxides or solid solutions thereof with other oxides, e.g. vanadates, niobates, tantalates, molybdates or tungstates
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/584 based on silicon nitride
• CPC Class Codes: C04B 35/806 The matrix of the ceramic products consisting of non-oxides only
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4539 as a 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 41/5027 Oxide ceramics in general; Specific oxide ceramics not covered by C04B41/5029 - C04B41/5051
• CPC Class Codes: C04B 41/5035 Silica
• CPC Class Codes: C04B 41/5042 Zirconium oxides or zirconates; Hafnium oxides or hafnates
• CPC Class Codes: C04B 41/5071 : Silicides
• CPC Class Codes: C04B 41/5096 : Silicon C04B35/573 takes precedence
• 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 41/85 : with inorganic materials
• CPC Class Codes: C04B 41/89 : for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: C23C 28/324 : with at least one metal matrix material layer comprising a mixture of at least two metals or metal phases or a metal-matrix material with hard embedded particles, e.g. WC-Me
• CPC Class Codes: C23C 28/34 : including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
• CPC Class Codes: C23C 28/345 : with at least one oxide layer
• CPC Class Codes: C23C 28/3455 : with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
• CPC Class Codes: C23C 28/36 : including layers graded in composition or physical properties
• CPC Class Codes: F01D 5/288 : Protective coatings for blades

Abstract

Components and methods of forming a protective coating system on the components are provided. In an embodiment, and by way of example only, the component includes a ceramic substrate and a braze layer disposed over the ceramic substrate. The braze layer includes a silicon matrix having a first constituent and a second constituent that is different than the first constituent. The first constituent forms a first intermetallic with a portion of the silicon matrix and the second constituent forms a second intermetallic with another portion of the silicon matrix, wherein the braze layer is formulated to provide a barrier to oxygen diffusion therethrough.

Claims

1. A coated component comprising:

a ceramic substrate; and

a braze layer disposed over the ceramic substrate, the braze layer including a silicon matrix having a first constituent and a second constituent that is different than the first constituent, the first constituent forming a first intermetallic with a portion of the silicon matrix and the second constituent forming a second intermetallic with another portion of the silicon matrix, wherein the braze layer is formulated to provide a barrier to oxygen diffusion therethrough.

2. The component of claim 1, wherein the silicon matrix consists essentially of pure silicon.

3. The component of claim 1, wherein the ceramic substrate comprises silicon carbide.

4. The component of claim 1, wherein the ceramic substrate comprises silicon nitride.

5. The component of claim 1, wherein the first constituent is selected from the group consisting of Ta, Mo, Sc, Yb, and Y.

6. The component of claim 1, wherein the second constituent is selected from the group consisting of Fe, Cr, V, Nb, Ti, Co, Hf, W, Ni, Pt, Re, and Mn.

7. The component of claim 1, wherein the first intermetallic comprises between about 10% and about 70% by volume of the braze layer, and the second intermetallic comprises between about 10% and about 70% by volume of the braze layer.

8. The component of claim 1, wherein the braze layer comprises a non-intermetallic forming constituent.

9. The component of claim 1, wherein the braze layer includes one or more additional intermetallic-forming constituents comprising one or more elements selected from the group consisting of Ta, Mo, Sc, Y, Yb, Fe, Cr, V, Nb, Ti, Co, Hf, W, Pt, Re, and Mn.

10. The component of claim 1, further comprising an environmental barrier coating disposed over the braze layer.

11. The component of claim 1, further comprising a thermal barrier coating disposed over the braze layer.

12. The component of claim 1, further comprising a scale layer disposed over the braze layer.

13. A component comprising:

a ceramic substrate; and

a protective coating system including;

a braze layer disposed over the ceramic substrate, the braze layer including a silicon matrix having a first intermetallic and a second intermetallic dispersed throughout the silicon matrix, the first intermetallic comprising a first constituent, and the second intermetallic comprising a second constituent that is different than the first constituent,

an environmental barrier coating disposed over the braze layer, and

a thermal barrier coating disposed over the environmental barrier coating,

wherein the braze layer is formulated to provide a barrier to oxygen diffusing through the thermal barrier coating and/or the environmental barrier coating.

14. The component of claim 13, wherein the first constituent is selected from the group consisting of Ta, Mo, Sc, Yb, and Y.

15. The component of claim 14, wherein the second constituent is selected from the group consisting of Fe, Cr, V, Nb, Ti, Co, Hf, W, Ni, Pt, Re, and Mn.

16. A method of forming a coating system on a component, the method comprising the steps of:

applying a braze mixture to a surface of the component, the braze mixture including silicon, a first constituent, and a second constituent that is different than the first constituent; and

heating the braze mixture to form a braze layer on the component, the braze layer comprising a portion of the coating system and including a silicon matrix with a first intermetallic including silicon and the first constituent and a second intermetallic including silicon and the second constituent.

17. The method of claim 16, wherein the first constituent is selected from the group consisting of Ta, Mo, Sc, Yb, and Y.

18. The method of claim 16, wherein the second constituent is selected from the group consisting of Fe, Cr, V, Nb, Ti, Co, Hf, W, Ni, Pt, Re, and Mn.

19. The method of claim 16, further comprising the step of forming an environmental barrier coating over the braze layer.

20. The method of claim 16, wherein the braze mixture further comprises one or more additional intermetallic-forming constituents comprising one or more elements selected from the group consisting of Ta, Mo, Sc, Y, Yb, Fe, Cr, V, Nb, Ti, Co, Hf, W, Pt, Re, and Mn.

21. The method of claim 16, further comprising the step of forming a thermal barrier coating over the braze layer.

22. The method of claim 16, further comprising the step of brazing the component to another silicon-base component with the braze mixture.