PART COATED WITH A SURFACE COATING AND ASSOCIATED METHODS

• US 20170159459A1
• Filed: 06/24/2015
• Published: 06/08/2017
• Est. Priority Date: 07/03/2014
• Status: Abandoned Application

• Current Assignee: Safran Ceramics
• Original Assignee: Safran Ceramics
• Inventors: COURCOT, Emilie, PHILIPPE, Eric, BOUILLON, Eric, JIMENEZ, Sbastien
• Application Number:
  US15/323,668
• Publication Number:
  US 20170159459A1
• Time in Patent Office: Days
• CPC Class Codes: C04B 2235/3826 Silicon carbides
• CPC Class Codes: C04B 2235/428 Silicon
• CPC Class Codes: C04B 2235/524 Non-oxidic, e.g. borides, carbides, silicides or nitrides
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/5445 submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/612 Machining
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/6562 Heating rate
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/6286 Carbides
• CPC Class Codes: C04B 35/62863 Silicon carbide
• CPC Class Codes: C04B 35/62868 Boron nitride
• CPC Class Codes: C04B 35/62873 Carbon
• CPC Class Codes: C04B 35/62884 by gas phase techniques
• CPC Class Codes: C04B 35/62894 with more than one coating layer
• CPC Class Codes: C04B 35/657 for manufacturing refractories C04B35/05, C04B35/107, C04B35/484 take precedence
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• 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 41/5096 : Silicon C04B35/573 takes precedence
• CPC Class Codes: C04B 41/5144 : with a composition mainly composed of one or more of the metals of the iron group
• CPC Class Codes: C04B 41/85 : with inorganic materials
• CPC Class Codes: C04B 41/88 : Metals
• CPC Class Codes: C23C 26/02 : applying molten material to the substrate
• CPC Class Codes: F01D 5/284 : Selection of ceramic materials
• CPC Class Codes: F01D 5/288 : Protective coatings for blades
• CPC Class Codes: F05D 2300/6033 : Ceramic matrix composites [CMC]
• CPC Class Codes: F05D 2300/611 : Coating
• CPC Class Codes: Y02T 50/60 : Efficient propulsion technologies, e.g. for aircraft

Abstract

A part made of composite material includes fiber reinforcement densified by a ceramic matrix. The part presents an outside surface and is coated over at least a portion of its outside surface by a surface coating in solid form including an alloy of silicon and nickel presenting a content by weight of silicon lying in the range 29% to 45%, or an alloy of silicon and cobalt.

Claims

1. A part made of composite material comprising fiber reinforcement densified by a ceramic matrix, the part presenting an outside surface, wherein the part is coated over at least a portion of the outside surface by a surface coating in solid form comprising an alloy of silicon and nickel presenting a content by weight of silicon lying in the range 29% to 45%, or an alloy of silicon and cobalt.

2. A part according to claim 1, wherein the surface coating comprises a phase of NiSi₂ and/or a phase of NiSi.

3. A part according to claim 1, wherein the surface coating comprises a phase of CoSi₂.

4. A part according to claim 1, wherein the alloy of silicon and nickel or of silicon and cobalt is present at a content by weight greater than or equal to 5% relative to a weight of the surface coating.

5. A part according to claim 1, wherein the surface coating further includes fillers and/or a ceramic material.

6. A part according to claim 1, wherein the alloy of silicon and cobalt presents a silicon content by weight lying in the range 34% to 90%.

7. A part according to claim 1, wherein the part constitutes an aeroengine blade comprising at least a blade root and an airfoil, and wherein the surface coating covers at least the blade root.

8. A turbine engine rotor wheel comprising:

a wheel disk having a blade fastener portion, said fastener portion comprising an alloy including nickel and/or cobalt; and

a part according to claim 7, fastened to the wheel disk, the blade root of the part being mounted in the blade fastener portion.

9. A method of fabricating a part according to claim 1, the method comprising:

a) infiltrating a fiber preform having a first set of fillers with an infiltration composition in the molten state, the infiltration composition comprising silicon and having a first melting temperature, so as to obtain, after putting the infiltration composition into contact with all or part of the fillers of the first set of fillers, a part made of composite material having fiber reinforcement densified by a ceramic matrix; and

b) applying on at least a portion of the outside surface of the part made of composite material an alloy in the molten state of silicon and nickel or of silicon and cobalt, the alloy of silicon and nickel or of silicon and cobalt having a second melting temperature lower than the first melting temperature in order to obtain a surface coating in solid form over at least a portion of the outside surface of the composite material part.

10. A method according to claim 9, further comprising, after step a) and before step b), a step c) of depositing on the outside surface of the composite material part a second set of fillers and/or a preceramic resin, and wherein the alloy in the molten state of silicon and nickel or of silicon and cobalt then infiltrates during step b) within the second set of fillers and/or preceramic resin in order to form the surface coating.

11. A method of fabricating a part according to claim 1, including a step:

of forming a surface coating in solid form on the outside surface of a part made of composite material comprising fiber reinforcement densified by a ceramic matrix, the surface coating comprising an alloy of silicon and nickel or of silicon and cobalt.

12. A method according to claim 11, wherein the forming of the surface coating comprises a step of putting an alloy in the molten state of silicon and nickel or of silicon and cobalt into contact with fillers and/or with a preceramic resin.

13. A method according to claim 12, wherein, prior to melting the alloy of silicon and nickel or of silicon and cobalt, the part is covered on the outside surface by a coating precursor layer including firstly the alloy of silicon and nickel or of silicon and cobalt, and secondly the fillers and/or the preceramic resin.