National Institute of Advanced Industrial Science and Technology

Teledyne Scientific and Imaging, LLC

Innovative Technology Licensing LLC

Peter E D Morgan

David Bruce Marshall

Janet B Davis

Olivier H Sudre

Tatsuki Ohji

Yoshikazu Suzuki

Aqueous precursor solutions are described that comprise at least one monazite-based material precursor, at least one xenotime-based material precursor or a combination thereof; and a plurality of fine suspended particles of an oxide material. Contemplated oxide composites, as described herein, comprise a plurality of fibers surrounded by at least one monazite or xenotime-based material, wherein the oxide composite has nearly a fully dense matrix. Contemplated embodiments disclosed herein provides a method for producing an oxide composite with nearly fully dense matrix and with all fibers surrounded by a monazite- or xenotime-based material that prevents embrittlement at temperatures at least as high as 1200&#xb0; C. Oxide composites are described that contain a plurality of fibers, a matrix containing at least one or more oxide materials, and at least one monazite-based material, xenotime-based material or combination thereof, wherein the monazite-based or xenotime-based material is formed from the aqueous precursor solutions disclosed herein. Contemplated methods of production include: a) providing a composite comprising oxide-reinforcing fibers and a porous matrix of oxide materials, and b) infiltrating the porosity in the matrix with a solution that contains precursors for at least one monazite-based material, at least one xenotime-based material or a combination thereof; and c) heat treating the composite to convert the precursors to monazite, xenotime, or combinations thereof.

Use of monazite or xenotime solution precursors to increase the density and shear strength of oxide composites

Monazites and xenotimes are rare-earth phosphates showing a combination of properties expected to be suitable for thermal barrier coatings. For example, lanthanum phosphate (La-monazite) can be used to form thermal barrier coatings to protect superalloy and ceramic parts exposed to high temperature and damage by sulfur, vanadium, phosphorus and other contaminants. The monazite or xenotime coatings can be applied using any of the common application methods including EB-PVD, laser ablation and plasma spraying. The stoichiometry of the coatings can be modulated according to the stoichiometry of specially prepared starting target (source) material. The most effective coatings appear to be largely crystalline and show a columnar structure with feather-like microstructure. For La-monazite, effective coatings between 10 and 500 micrometers in thickness can be deposited on substrates having temperatures between about 750&#xb0; C. and about 950&#xb0; C.

Monazite-based thermal barrier coatings

The present invention relates to porous calcium zirconate/magnesia composites having a thermally and chemically stable porous structure, which consist of sintered compacts having a fine composite structure stable under high temperatures due to uniformly dispersed equimolar amounts of calcium zirconate &lsqb;CazrO &rsqb; and magnesia &lsqb;MgO&rsqb; and controlled grain growth, and a method of producing the same, and the present porous composites are useful as, for instance, a functional material for filtering highly corrosion resistant materials, lightening members used at super-high temperatures, catalyst carriers, insulation or sound-absorbing materials, and the like.

Calcium zirconate/magnesia porous composites and their fabrication process

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Thousand Oaks, CA, United States of America

Peter E D Morgan