Rolls-royce Corporation

Rolls-royce High Temperature Composites Inc.

Rolls-royce North American Technologies Inc.

Lee, Kang N.

Kang N Lee

Andrew Joseph Lazur

Adam Lee Chamberlain

Sungbo Shim

Robert J Shinavski

Stephen Isaiah Harris

Ted Joseph Freeman

David John Thomas

Sean E Landwehr

Matthew R Gold

Richard Christopher Uskert

Michael Cybulsky

Robert Wesley Thibault

Jun Shi

Ann Bolcavage

Raymond John Sinatra

Richard W Kidd

Benjamin John Bowin Lai

A method of making a fiber tow coating is provided. The method includes providing a fiber tow selected from the group consisting of carbon and silicon; and applying an oxide-based fiber interface coating onto the fiber tow using directed vapor deposition or other like deposition method.

Coating fibers using directed vapor deposition

An article may include a substrate defining at least one at least partially obstructed surface. The substrate includes at least one of a ceramic or a ceramic matrix composite. The article also may include a multilayer, multi-microstructure environmental barrier coating on the at least partially obstructed substrate. The multilayer, multi-microstructure environmental barrier coating includes a first layer comprising a rare earth disilicate and a substantially dense microstructure; and a second layer on the first layer. The second layer includes a columnar microstructure and at least one of a rare earth monosilicate or a thermal barrier coating composition comprising a base oxide comprising zirconia or hafnia; a primary dopant comprising ytterbia; a first co-dopant comprising samaria; and a second co-dopant comprising at least one of lutetia, scandia, ceria, gadolinia, neodymia, or europia.

Plasma spray physical vapor deposition deposited in multilayer, multi-microstructure environmental barrier coating

In some examples, a method may include depositing, from a slurry comprising particles including silicon metal, a bond coat precursor layer including the particles comprising silicon metal directly on a ceramic matrix composite substrate. The method also may include locally heating the bond coat precursor layer to form a bond coat comprising silicon metal. Additionally, the method may include forming a protective coating on the bond coat. In some examples, an article may include a ceramic matrix composite substrate, a bond coat directly on the substrate, and a protective coating on the bond coat. The bond coat may include silicon metal and a metal comprising at least one of Zr, Y, Yb, Hf, Ti, Al, Cr, Mo, Nb, Ta, or a rare earth metal.

Applying silicon metal-containing bond layer to ceramic or ceramic matrix composite substrates

The disclosure describes techniques for forming a surface layer of an article including a CMC using a cast. In some examples, the surface layer includes three-dimensional surface features, which may increase adhesion between the CMC and a coating on the CMC. In some examples, the surface layer may include excess material, with or without three-dimensional surface features, which is on the CMC. The excess material may be machined to remove some of the excess material and facilitate conforming the article to dimensional tolerances, e.g., for fitting the article to another component. The excess material may reduce a likelihood that the CMC (e.g., reinforcement material in the CMC) is damaged by the machining.

Forming a surface layer of a ceramic matrix composite article

A blade and method for producing the blade for a gas turbine engine are described herein. The blade may include a composite airfoil. The airfoil may comprise a ceramic material, and a distal end. A tip may extend from the distal end of the airfoil. The tip of the airfoil may comprise a substantially porous structure and may comprise infiltrated material extending from an airfoil preform to a tip preform to join the airfoil preform and the tip preform.

Abrasive tips for ceramic matrix composite blades and methods for making the same

An article may include a substrate, a plurality of cooling holes in the substrate, wherein each of the plurality of cooling holes defines substantially the same diameter measured parallel to an outer surface of the substrate, and a coating on the surface of the substrate. In accordance with these examples, the coating covers and substantially blocks a first set of cooling holes from the plurality of cooling holes and leaves a second set of cooling holes from the plurality of cooling holes substantially uncovered. In some examples, an article including a substrate, a plurality of cooling holes in the substrate, and a coating on the substrate. In accordance with these examples, the coating covers and partially occludes each cooling hole of the plurality of cooling holes, and the coating does not extend into any of the plurality of cooling holes.

Damage tolerant cooling of high temperature mechanical system component including a coating

A coating including a bond layer deposited on a substrate. The bond layer includes a rare earth silicate and a second phase, the second phase including at least one of silicon, silicides, alkali metal oxides, alkali earth metal oxides, glass ceramics, AlO, TiO, TaO, HfO, ZrO, HfSiO, ZrSiO, HfTiO, ZrTiO, or mullite. The coating may provide thermal and/or environmental protection for the substrate, especially when the substrate is a component of a high-temperature mechanical system.

Coating including a rare earth silicate-based layer including a second phase

A ceramic matrix composite component for use in a gas turbine engine and method for making the same are described herein. The component includes a body and an outer region. The body includes a silicon containing ceramic composite. The outer region is on an outer surface of the body.

Modified atmosphere melt infiltration

Example techniques may include depositing a slurry on at least a predetermined surface region of a ceramic matrix composite substrate. The slurry may include a solvent and particles comprising at least one of silicon metal or silicon carbide. The slurry may be dried to form a wicking layer on the predetermined surface region. The ceramic matrix composite substrate and the wicking layer may be heated to a temperature of at least 900&#xb0; C. to wick at least one wickable species from the ceramic matrix composite substrate into the wicking layer. Substantially all of the wicking layer may be removed from the predetermined surface region. Example articles may include a ceramic matrix composite substrate. A wicking layer may be disposed on at least a predetermined surface region of the ceramic matrix composite substrate. The wicking layer may include at least one wicked species wicked from the ceramic matrix composite substrate.

Reducing impurities in ceramic matrix composites

An article having a substrate that includes a ceramic or a ceramic matrix composite, a bond layer on the substrate that includes silicon metal and a boria stabilizing agent, and at least one additional layer on the bond layer.

Bond layer for ceramic or ceramic matrix composite

In some examples, a coating may include at least one feature that facilitates visual determination of a thickness of the coating. For example, the coating may include a plurality of microspheres disposed at a predetermined depth of the coating. The plurality of microspheres may define a distinct visual characteristic. By inspecting the coating and viewing at least one of the microspheres, the thickness of the coating may be estimated. In some examples, the plurality of microspheres may be embedded in a matrix material, and the distinct visual characteristic of the microspheres may be different than the visual characteristic of the matrix material. In other examples, the at least one feature may include at least one distinct layer in the coating system that includes a distinct visual characteristic, such as a color of the distinct layer.

Visual indicator of coating thickness

A method of making a multilayer environmental barrier coating for a ceramic matrix composite is provided, comprising the steps of: plasma spray coating an oxide-based bond coat over top of the ceramic matrix composite and depositing a columnar top coat over the oxide-based bond coat.

Growing community of inventors

Zionsville, IN, United States of America

Kang N Lee