STRUCTURE AND METHOD FOR PROTECTING A HYBRID CERAMIC STRUCTURE FROM MOISTURE ATTACK IN A HIGH TEMPERATURE ENVIRONMENT

• US 20100021713A1
• Filed: 07/22/2008
• Published: 01/28/2010
• Est. Priority Date: 07/22/2008
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Power Generation, Inc.
• Inventors: Lane, Jay E., Merrill, Gary B.
• Granted Patent: US 9,328,028 B2
• Time in Patent Office: Days
• US Class Current: 428/304.400
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: C04B 28/34 containing cold phosphate binders
• CPC Class Codes: C04B 35/803 The matrix of the ceramic products consisting of oxides only
• 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 41/457 Non-superficial impregnation or infiltration of the substrate
• CPC Class Codes: C04B 41/5024 Silicates C04B41/5022 takes precedence; silico-fluorides C04B41/5018
• CPC Class Codes: C04B 41/5025 with ceramic materials copper oxide or solid solutions thereof C04B41/5074
• CPC Class Codes: C04B 41/5032 Aluminates aluminate spinels C04B41/5046
• CPC Class Codes: C04B 41/5042 Zirconium oxides or zirconates; Hafnium oxides or hafnates
• CPC Class Codes: C04B 41/5044 Hafnates
• CPC Class Codes: C04B 41/5045 Rare-earth oxides
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

A hybrid ceramic structure and a method for protecting the hybrid ceramic structure from moisture attack in a high temperature combustion environment are provided. The structure includes a ceramic matrix composite (CMC) substrate (12). A thermal insulation material (14) is disposed on the substrate. A vapor resistant material (20) is applied through at least one surface of the hybrid ceramic structure while the hybrid ceramic structure is in a bisque condition that provides a degree of porosity to the hybrid ceramic structure so that the vapor resistant material is infiltrated through interstices available within a thickness of the hybrid ceramic structure.

Claims

1. A hybrid ceramic structure for use in a high temperature combustion environment containing moisture, the structure comprising:

a ceramic matrix composite (CMC) substrate;

a thermal insulation material disposed on the substrate;

a vapor resistant material applied through at least one surface of the hybrid ceramic structure while the hybrid ceramic structure is in a bisque condition, which provides a degree of porosity to the hybrid ceramic structure, so that the vapor resistant material is infiltrated through interstices available within a thickness of the hybrid ceramic structure, wherein the vapor resistant material forms a coating of vapor resistant material at least on said at least one surface of the hybrid ceramic structure and on respective inner surfaces of the interstices available within the thickness of the hybrid ceramic structure.

2. The hybrid ceramic structure of claim 1, wherein the vapor resistant material is applied through a surface of the thermal insulation material, and the thickness of the hybrid ceramic structure comprises at least a portion of the thermal insulation material.

3. The hybrid ceramic structure of claim 2, wherein the thickness of the hybrid ceramic structure extends from the surface of the thermal insulation material up to a portion of the ceramic matrix composite (CMC) substrate.

4. The hybrid ceramic structure of claim 2, wherein the thickness of the hybrid ceramic structure extends from the surface of the thermal insulation material and includes an entire thickness of the ceramic matrix composite (CMC) substrate.

5. The hybrid ceramic structure of claim 1, wherein the vapor resistant material is applied through a surface of the ceramic matrix composite (CMC) substrate, and the thickness of the hybrid ceramic structure comprises at least a portion of the ceramic matrix composite (CMC) substrate.

6. The hybrid ceramic structure of claim 5, wherein the thickness of the hybrid ceramic structure extends from the surface of the ceramic matrix composite (CMC) substrate up to a portion of the thermal insulation material.

7. The hybrid ceramic structure of claim 5, wherein the thickness of the hybrid ceramic structure extends from the surface of the ceramic matrix composite (CMC) substrate and includes an entire thickness of the thermal insulation material.

8. The hybrid ceramic structure of claim 1, wherein the vapor resistant material is applied through surfaces of the thermal insulation material and the ceramic matrix composite (CMC) substrate, wherein the thickness of the hybrid ceramic structure comprises a first thickness corresponding to at least a portion of the ceramic matrix composite (CMC) substrate and a second thickness corresponding to at least a portion of the thermal insulation material.

9. The hybrid ceramic structure of claim 1, wherein the thermal insulation material comprises a plurality of geometric shapes packed in a binder material, wherein at least some of the interstices of the hybrid structure are disposed within said binder material.

10. The hybrid ceramic structure of claim 9, wherein the vapor resistant material infiltrates into the binder material to densify a body formed by the binder material.

11. The hybrid ceramic structure of claim 1, wherein the vapor resistant material does not fully fill at least some of the interstices available within the thickness of the hybrid ceramic structure.

12. The hybrid ceramic structure of claim 1, wherein the vapor resistant material fills at least some of the interstices available within the thickness of the hybrid ceramic structure.

13. The hybrid ceramic structure of claim 1, wherein the coating of vapor resistant material ranges in thickness from 0.11 microns to 50 microns on the respective inner surfaces of the interstices available within the thickness of the hybrid ceramic structure.

22. The hybrid ceramic structure of claim 1, wherein the vapor resistant material is selected from the group consisting of a pyrochlore structure;

HfSiO₄;

ZrSiO₄;

Y₂Si₂O₇;

Y₂O₃;

ZrO₂, HfO₂;

yttria and/or ZrO₂ stabilized by at least one rare earth element;

yttria and/or HfO₂ stabilized by at least one rare earth element, yttria and/or ZrO₂/HfO₂ stabilized by at least one rare earth element;

a rare earth silicate of the form RE₂Si₂O₇;

a rare earth oxide of the form RE₂O₃; and

a rare earth zirconate or hafnate of the form RE₄Zr₃O₁₂ or RE₄Hf₃O₁₂, wherein the rare earth element is selected from the group consisting of;

Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu.

14-21. -21. (canceled)