Material system of co-sintered metal and ceramic layers
First Claim
1. A method of fabricating a metal and ceramic layered material system, comprising:
- selecting a metal material and a ceramic material with respective coefficients of thermal expansion that are within 15% of each other throughout an operating temperature range plus a co-sintering temperature range;
forming a substrate from a powder of the metal material;
disposing a layer on the substrate, wherein the layer comprises a powder of the ceramic material containing at least 2% by volume of ceramic nano-particles having an average diameter of less than 100 nm;
co-sintering the substrate and the layer within the co-sintering temperature range to a final density of the substrate of at least 97% theoretical density; and
selecting the metal material, the ceramic material, and the percentage of ceramic nano-particles such that the co-sintering produces respective shrinkage amounts of the layer and the substrate that are within 1.0% of each other throughout the co-sintering thereof.
6 Assignments
0 Petitions
Accused Products
Abstract
A method of forming a ceramic layer on a metal substrate. A substrate (40) is formed (54) from a powder (24) of the metal, and may optionally be partially sintered (56). A layer (43) of powdered ceramic is formed (58) on or applied against the substrate (45). The ceramic powder may include a proportion of nano-sized particles effective to reduce the ceramic sintering temperature and to increase the sintering shrinkage of the ceramic layer to more closely match that of the metal substrate. The substrate and layer are then co-sintered (21, 60) at a temperature and for a duration that densifies and bonds them, producing a metal/ceramic layered material system with low interface stress that is durable to temperature variations in a gas turbine. Spark plasma sintering (32, 34, 36) may be used to sinter and/or co-sinter substrate and layer materials that normally cannot be sintered.
-
Citations
17 Claims
-
1. A method of fabricating a metal and ceramic layered material system, comprising:
-
selecting a metal material and a ceramic material with respective coefficients of thermal expansion that are within 15% of each other throughout an operating temperature range plus a co-sintering temperature range; forming a substrate from a powder of the metal material; disposing a layer on the substrate, wherein the layer comprises a powder of the ceramic material containing at least 2% by volume of ceramic nano-particles having an average diameter of less than 100 nm; co-sintering the substrate and the layer within the co-sintering temperature range to a final density of the substrate of at least 97% theoretical density; and selecting the metal material, the ceramic material, and the percentage of ceramic nano-particles such that the co-sintering produces respective shrinkage amounts of the layer and the substrate that are within 1.0% of each other throughout the co-sintering thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7)
-
-
8. A method of fabricating a metal and ceramic layered material system, comprising:
-
selecting a metal material and a ceramic material with respective coefficients of thermal expansion that are within 15% of each other throughout a temperature range of 0-1400°
C.;forming a substrate comprising engineered interlocking surface features from a powder of the metal material; partially sintering the substrate to produce a pre-sintered substrate; disposing a layer on the pre-sintered substrate, wherein the layer comprises a powder of the ceramic material containing 2% to 50% by volume of ceramic nano-particles having an average diameter of less than 100 nm; co-sintering the pre-sintered substrate and the layer enough to achieve a final density of the substrate of at least 97% theoretical density; and selecting the metal material, the ceramic material, the percentage of ceramic nano-particles, and a degree of the partial sintering, wherein the co-sintering produces respective shrinkage amounts of the layer and the pre-sintered substrate that are within 1.0% of each other throughout the co-sintering thereof. - View Dependent Claims (9)
-
-
10. A method of fabricating a metal and ceramic layered material system, comprising:
-
forming a substrate comprising particles of a metal material; forming a layer comprising particles of a ceramic material comprising a particle size distribution including 5% to 40% of the particles being less than 50 nm in average diameter; co-sintering the layer onto the substrate with a co-processing cycle wherein a sintering shrinkage of the substrate and a sintering shrinkage of the layer stay within 1.0% of each other throughout the co-sintering to form a chemical bond between the substrate and the layer comprising interspersed elements of both the metal material and the ceramic material. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17)
-
Specification