CERAMIC ATTACHMENT CONFIGURATION AND METHOD FOR MANUFACTURING SAME

• US 20160251972A1
• Filed: 10/10/2014
• Published: 09/01/2016
• Est. Priority Date: 10/21/2013
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Dierberger, James A.
• Granted Patent: US 10,287,899 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4523 applied from the molten state vitreous materials C04B41/5022; Thermal spraying, e.g. plasma spraying
• CPC Class Codes: C04B 41/4527 Plasma spraying deposition from the gas phase using plasma C04B41/4533
• CPC Class Codes: C04B 41/4529 applied from the gas phase
• CPC Class Codes: C04B 41/4531 by C.V.D.
• CPC Class Codes: C04B 41/4582 Porous coatings, e.g. coating containing porous fillers
• CPC Class Codes: C04B 41/5025 with ceramic materials copper oxide or solid solutions thereof C04B41/5074
• CPC Class Codes: C04B 41/87 Ceramics
• CPC Class Codes: C23C 14/0635 Carbides
• CPC Class Codes: C23C 14/0652 Silicon nitride
• CPC Class Codes: C23C 14/083 of refractory metals or yttrium
• CPC Class Codes: C23C 14/30 by electron bombardment
• CPC Class Codes: C23C 16/325 Silicon carbide
• CPC Class Codes: C23C 16/345 Silicon nitride
• CPC Class Codes: C23C 16/405 of refractory metals or yttrium
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: C23C 4/10 Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
• CPC Class Codes: C23C 4/11 Oxides
• CPC Class Codes: C23C 4/129 Flame spraying
• CPC Class Codes: C23C 4/134 : Plasma spraying
• CPC Class Codes: F01D 5/284 : Selection of ceramic materials
• CPC Class Codes: F01D 5/288 : Protective coatings for blades
• CPC Class Codes: F01D 5/3007 : of axial insertion type
• CPC Class Codes: F01D 5/3092 : Protective layers between blade root and rotor disc surfaces, e.g. anti-friction layers F01D5/288 takes precedence
• CPC Class Codes: F05D 2220/32 : in gas turbines
• CPC Class Codes: F05D 2230/311 : by torch or flame spraying
• CPC Class Codes: F05D 2230/312 : by plasma spraying
• CPC Class Codes: F05D 2230/313 : by physical vapour deposition
• CPC Class Codes: F05D 2230/314 : by chemical vapour deposition
• CPC Class Codes: F05D 2240/24 : for turbines
• CPC Class Codes: F05D 2300/20 : Oxide or non-oxide ceramics
• CPC Class Codes: F05D 2300/514 : Porosity
• CPC Class Codes: F05D 2300/6033 : Ceramic matrix composites [CMC]
• CPC Class Codes: F05D 2300/612 : Foam

Abstract

A component assembly includes a support structure, a ceramic substrate mounted to the support, and a foam-like coating adhered to one of the support structure and the ceramic substrate. The foam-like coating engages the other of the support structure and the ceramic substrate.

Claims

1. A component assembly comprising:

a support structure;

a ceramic substrate mounted to the support; and

a foam-like coating adhered to one of the support structure and the ceramic substrate, and the foam-like coating engaging the other of the support structure and the ceramic substrate.

2. The assembly according to claim 1, wherein the support structure is metallic.

3. The assembly according to claim 1, wherein the foam-like coating is a porous metal.

4. The assembly according to claim 3, wherein the porous metal is at least one of copper and aluminum.

5. The assembly according to claim 1, wherein the foam-like coating is one of a ceramic matrix composite and a monolithic ceramic.

6. The assembly according to claim 5, wherein the foam-like coating is at least one of a carbide and an oxide.

7. The assembly according to claim 6, wherein the foam-like coating is zirconia.

8. The assembly according to claim 1, wherein the foam-like coating is adhered to the ceramic substrate.

9. The assembly according to claim 1, wherein the foam-like coating has filaments intersecting one another to provide voids creating a flexible layer.

10. The assembly according to claim 9, wherein the foam-like coating has a thickness of up to 5 mils (127 micrometers).

11. The assembly according to claim 1, wherein the support structure is a rotor having a slot, and comprising a blade including a root that provides the ceramic substrate, the root received in the slot.

12. The assembly according to claim 11, wherein the foam-like coating is adhered to the root.

13. The assembly according to claim 11, wherein the foam-like coating is adhered to the slot.

14. The assembly according to claim 11, wherein the foam-like coating is configured to transfer a force from a high point on the support to the ceramic substrate without cracking a surface of the ceramic substrate with which the foam-like coating is in engagement.

15. The assembly according to claim 14, wherein the foam-like coating is configured to flex in response to the force.

16. A method of manufacturing a component assembly, the method comprising the steps of:

depositing ceramic onto a rigid ceramic substrate to produce a flexible foam-like coating having a porosity of less than 30%.

17. The method according to claim 16, wherein the depositing step includes one of chemical vapor deposition, electron beam physical vapor deposition, flame spraying and plasma spraying.

18. The method according to claim 16, wherein the foam-like coating includes filaments intersecting one another to provide voids creating a flexible layer having a thickness of up to 5 mils (127 micrometers).

19. The method according to claim 16, comprising a blade including a root that provides the ceramic substrate, and including the step of installing the root into a rotor slot, wherein the foam-like coating is configured to transfer a force from a high point on the rotor slot to the ceramic substrate by flexing without cracking a surface of the root.

20. The method according to claim 16, wherein the ceramic substrate is one of a ceramic matrix composite and a monolithic ceramic.