Method of producing a functionally gradient material

• US 4,751,099 A
• Filed: 12/24/1986
• Issued: 06/14/1988
• Est. Priority Date: 12/28/1985
• Status: Expired due to Term

• Current Assignee: Daikin Industries Ltd, National Aerospace Laboratory of Science & Technology, Ryuzo Watanabe, Sumitomo Electric Industries Limited (Sumitomo Corporation), Toshio Hirai
• Original Assignee: Daikin Industries Ltd, National Aerospace Laboratory of Science & Technology, Ryuzo Watanabe, Sumitomo Electric Industries Limited (Sumitomo Corporation), Toshio Hirai
• Inventors: Suzuki, Akio, Hirai, Toshio, Watanabe, Ryuzo, Kuroishi, Nobuhito, Niino, Masayuki, Hirano, Tohru
• Primary Examiner(s): Newsome, John H.
• Application Number:
  US06/947,419
• Time in Patent Office: 538 Days
• Field of Search: 427/34, 427/201, 427/423, 428/547, 428/610, 419/5
• US Class Current: 427/450
• CPC Class Codes: B22F 2207/01 Composition gradients
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 3/1109 Inhomogenous pore distribution composite layers of porous nature B22F7/002
• CPC Class Codes: B22F 7/02 of composite layers B22F7/002 takes precedence
• CPC Class Codes: C23C 14/027 Graded interfaces
• CPC Class Codes: C23C 14/0688 Cermets, e.g. mixtures of metal and one or more of carbides, nitrides, oxides or borides
• CPC Class Codes: C23C 14/22 characterised by the process of coating
• CPC Class Codes: C23C 16/029 Graded interfaces
• CPC Class Codes: C23C 16/30 Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
• CPC Class Codes: C23C 16/44 characterised by the method of coating C23C16/04 takes precedence
• CPC Class Codes: C23C 28/3215 at least one MCrAlX 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: C23C 4/02 Pretreatment of the material to be coated, e.g. for coating on selected surface areas
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

The present invention relates to a method of producing a functionally grant material whose components and structure are continuously adjusted by the coating, plating and powder metallurgy techniques to change its function in turn and provide a method of producing a functionally gradient material superior in heat-resistance, corrosion-resistance and resistance to thermal fatigue by distributing a third component having a lower Young'"'"'s modulus or formed of high-strength material sufficiently durable to the fracture strength among ceramics as a first component and metals or other ceramics as a second component to change the function.

Claims

1. A method of producing a functionally gradient material, in which a composite material, in which an intermediate layer with a continuously changing ratio of a second component to a first component is arranged between a ceramics as said first component and a metal or another ceramics as said second component, is produced, characterized in that a component having a lower Young'"'"'s modulus or a high-strength material as a third component is distributed in said intermediate layer.

2. A method of producing a functionally gradient material as set forth in claim 1, characterized in that said third component is distributed so that the specific stress distribution R (R=thermal stress/mixture average compression fracture stress) may be equalized and an average value of R may be reduced.

3. A method of producing a functionally gradient material as set forth in claim 1, characterized in that said first component is C, said second component being SiC, and said third component being either TiC or micropores or both TiC and micropores.

4. A method of producing a functionally gradient material as set forth in claim 1, characterized in that said first component is ZrO₂.Y₂ O₃, said second component is MCrAlY (M:

metal), and said third component are micropores.

5. A method of producing a functionally gradient material as set forth in claim 1, characterized in that micropores are distributed as said third component and the powder metallurgical technology, in which a particle diameter of raw material powders is adjusted, is used for the formation of the distribution of said micropores.