Solid joint obtained by heat projection

• US 8,431,254 B2
• Filed: 10/09/2006
• Issued: 04/30/2013
• Est. Priority Date: 10/11/2005
• Status: Expired due to Fees

• Current Assignee: Commissariat a L'Energie Atomique (French Alternative Energies and Atomic Energy Commission)
• Original Assignee: Commissariat a L'Energie Atomique (French Alternative Energies and Atomic Energy Commission)
• Inventors: Bianchi, Luc, Bories, Charles, Toulc'Hoat, Joel
• Primary Examiner(s): Katz, Vera
• Application Number:
  US12/083,389
• Publication Number:
  US 20090199947A1
• Time in Patent Office: 2,395 Days
• Field of Search: None
• US Class Current: 428/698
• CPC Class Codes: C04B 2235/36 Glass starting materials for making ceramics, e.g. silica glass
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C23C 24/04 Impact or kinetic deposition of particles
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: C23C 4/185 Separation of the coating from the substrate
• CPC Class Codes: F16J 15/0806 characterised by material or surface treatment
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 8/0276 Sealing means characterised by their form H01M8/0273 takes precedence
• CPC Class Codes: H01M 8/028 Sealing means characterised by their material
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/12007 Component of composite having metal continuous phase interengaged with nonmetal continuous phase
• CPC Class Codes: Y10T 428/12451 Macroscopically anomalous interface between layers
• CPC Class Codes: Y10T 428/12472 Microscopic interfacial wave or roughness
• CPC Class Codes: Y10T 428/12479 Porous [e.g., foamed, spongy, cracked, etc.]
• CPC Class Codes: Y10T 428/24471 Crackled, crazed or slit

Abstract

The invention relates to a composite material element (1), the composite material comprising a microfissured matrix (7) in the form of a three-dimensional interconnected network (4) of microfissures exposed on the surface of the ceramic matrix, an additive material (6) consisting of a flux or glass being dispersed in the matrix, the additive material (6) being a material which, when the composite material is brought to a predetermined temperature, softens and migrates by capillarity in the network (4) of microfissures (4) to said surface of the element. The quantity of additive material dispersed initially in the matrix is in a sufficient proportion compared to the matrix intended to coat a surface (5) of the composite material element left exposed so as to create a gas-tight barrier.

Claims

1. A composite material element, the composite material element comprising a microfissured ceramic matrix forming a three-dimensional interconnected network of microfissures created by relaxation of thermal stresses and exposed on a surface of the matrix, the microfissured ceramic matrix consisting of at least one material chosen from among metal, metallic alloys, metallic oxides, carbides, nitrides, silicides and borides, a quantity of additive material consisting of at least one material chosen from among a glass, a ceramic flux, a metal and a metallic alloy, being dispersed in the matrix, the additive material being a material chosen to soften and migrate by capillarity in the network of microfissures to a surface of the element when the composite material element is brought to a predetermined temperature, the quantity of additive material dispersed in the matrix being in a sufficient proportion, compared to the matrix, to coat a surface of the composite material element left exposed so as to create there a gas-tight barrier.

2. Composite material element according to claim 1, comprising between 5% and 85% by weight of additive material.

3. Composite material element according to claim 1, in which said predetermined temperature is a temperature in the range extending from 100°

C. to 1500°

C.

4. Solid joint constituted from a composite material element according to claim 1, this composite material having been brought to said predetermined temperature in order that a coating of additive material covers said surface left exposed.

5. Solid joint according to claim 4, in which the composite material element is an element deposited initially so as to adhere by thermal spraying to a first part, the additive material coating covering said surface left exposed to provide said gas-tight barrier with a second part opposite this surface left exposed.

6. Solid joint according to claim 4, in which the composite material element is an auto-structuring element, wherein an element initially having a surface left exposed for a first part to be joined and a surface left exposed for a second part to be joined, a coating of additive material covering the surfaces left exposed to provide a gas-tight barrier with each of the two parts.

7. Method for manufacturing a composite material element according to claim 1, comprising a step of thermal spraying of a material intended to form the ceramic matrix and a material intended to form the additive material, on at least one recipient surface.

8. Method according to claim 7, in which thermal spraying is chosen from among the techniques of plasma spraying, oxyacetylene flame spraying, HVOF spraying, HVAF spraying, detonation gun spraying, wire arc and powder arc spraying, direct current arc plasma spraying, inductive plasma spraying, cold dynamic spraying and a combination of at least two of these techniques.

9. Method according to claim 7, in which the recipient surface is a surface of a first part intended to be bonded to a second part by means of the solid joint.

10. Method for manufacturing a leakproof solid joint comprising:

application of the method according to claim 9 to said surface of the first part,

placement of a surface of said second part opposite said surface left exposed,

bringing of the composite material element to said predetermined temperature to obtain the coating of said surface left exposed, said coating capable of adhering to the surface of said second part placed opposite it.

11. Method according to claim 10, in which a pressure is exerted between the first and second part, tending to draw the first surface of the first part closer to the second surface of the second part, while it is being brought to said predetermined temperature, in order to improve adherence of the coating or coatings.

12. Method according to claim 7, in which the recipient surface is a stripping interface for recovery of the composite material element.

13. Method for manufacturing a leakproof solid joint, comprising:

interposing of the composite material element obtained by the method according to claim 12 between a first surface of a first part and a second surface of a second part, the first surface and the second surface being opposite each other,

bringing the composite material element to said predetermined temperature to obtain coatings on the surfaces of the composite material element left exposed, said coatings adhering to the first surface of the first part and the second surface of the second part.

14. Method according to claim 13, in which a pressure is exerted between the first and second part, tending to draw the first surface of the first part closer to the second surface of the second part, while it is being brought to said predetermined temperature, in order to improve adherence of the coating or coatings.

15. Method according to claim 7, in which a porogenic material is also sprayed during the thermal spraying step.