Reducing wear between structural fiber reinforced ceramic matrix composite parts

• US 5,985,205 A
• Filed: 10/29/1997
• Issued: 11/16/1999
• Est. Priority Date: 08/16/1995
• Status: Expired due to Term

• Current Assignee: Northrop Grumman Systems Corporation (Northrop Grumman Corporation)
• Original Assignee: Northrop Grumman Corporation
• Inventors: Atmur, Steven Donald, Strasser, Thomas Edward
• Primary Examiner(s): Fiorilla, Christopher A.
• Application Number:
  US08/967,207
• Time in Patent Office: 748 Days
• Field of Search: 264/624, 264/625, 264/626, 264/446, 427/446, 427/450, 427/451, 427/452, 427/453, 427/292, 427/314
• US Class Current: 264/624
• CPC Class Codes: C04B 2111/00353 Sliding parts
• CPC Class Codes: C04B 2111/20 Resistance against chemical, physical or biological attack
• CPC Class Codes: C04B 35/18 rich in aluminium oxide
• CPC Class Codes: C04B 35/571 obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• 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 41/4523 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 41/4554 the coating or impregnating material being an organic or organo-metallic precursor of an inorganic material
• CPC Class Codes: C04B 41/5025 with ceramic materials copper oxide or solid solutions thereof C04B41/5074
• CPC Class Codes: C04B 41/5031 Alumina
• CPC Class Codes: C04B 41/5037 Clay, Kaolin
• 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 41/522 Multiple coatings, for one of the coatings of which at least one alternative is described
• CPC Class Codes: C04B 41/53 involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete C04B41/0036 - C04B41/0054 take precedence
• CPC Class Codes: C04B 41/87 Ceramics
• CPC Class Codes: C04B 41/89 for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: C23C 4/00 Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge build-up welding B23K, e.g. B23K5/18, B23K9/04
• CPC Class Codes: C23C 4/10 Oxides, borides, carbides, nitrides or silicides; Mixtures thereof

Abstract

Structural ceramic matrix composite material to be employed as automotive engine parts and the like is provided with erosion-resistant qualities in several ways. For one, an erosion-resistant material is applied to the surface as by plasma spraying. The erosion-resistant material can also be mixed with the fibers of the material, particularly near the surface.

Claims

1. A method for fabricating a plurality of fiber-reinforced ceramic matrix composite parts slidingly interactive with each other, the method comprising:

a) constructing a first part and a second part from a pre-ceramic polymer resin having fibers of a non-woven generic fiber system dispersed throughout;

b) shaping an exposed portion of the first part into a substantially flat first surface and an exposed portion of the second part into a substantially flat second surface, wherein the first and second surfaces are complimentarily shaped to slidingly engage each other;

c) firing the first and second parts at a temperature and for a time sufficient to convert the resin into a ceramic; and

d) bondingly coating an erosion resistant material to said first and second flat surfaces for sliding engagement with each other.

2. A method for fabricating a plurality of fiber-reinforced ceramic matrix composite parts as claimed in claim 1 wherein said erosion resistant material is bondingly coated with a plasma spray.

3. A method for fabricating a plurality of fiber-reinforced ceramic matrix composite parts as claimed in claim 1 wherein said erosion resistant material is chosen from the group consisting of mullite, alumina, and a mixture thereof.

4. A method for fabricating a plurality of fiber-reinforced ceramic matrix composite parts as claimed in claim 1 wherein prior to bondingly coating the erosion resistant material said first and second flat surfaces are grit-blasted to create divots and expose fiber hairs.

5. A method for fabricating a plurality of fiber-reinforced ceramic matrix composite parts as claimed in claim 1 wherein prior to bondingly coating the erosion resistant material said first and second flat surfaces are grooved with a plurality of thin, shallow, close-spaced grooves.

6. A method for fabricating a plurality of fiber-reinforced ceramic matrix composite parts slidingly interactive with each other, the method comprising:

a) constructing a first part and a second part from a pre-ceramic polymer resin having fibers of a non-woven generic fiber system dispersed throughout and an erosion resistant material;

b) shaping an exposed portion of the first part into a substantially flat first surface and an exposed portion of the second part into a substantially flat second surface, wherein the first and second surfaces are complimentarily shaped to slidingly engage each other; and

c) firing the first and second parts at a temperature and for a time sufficient to convert the resin into a ceramic.

7. A method for fabricating a plurality of fiber-reinforced ceramic matrix composite parts as claimed in claim 6 wherein said erosion resistant material is chosen from the group consisting of mullite, alumina, and a mixture thereof.