Mcdonnell Douglas Corporation

Siemens Power Generation, Inc.

Robert William Kreutzer

Robert A DiChiara, Jr

Jay Alan Morrison

Gary Brian Merrill

Jay Edgar Lane

Steven C Butner

Bryan Imber

A composite material () formed of a ceramic matrix composite (CMC) material () protected by a ceramic insulating material (). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material () may be used in the insulating material in order to avoid degradation of the fabric () of the CMC material during the co-firing step.

Methods of manufacturing insulated ceramic matrix composite

Insulated ceramic matrix composite and method of manufacturing

An article is fabricated with a ceramic surface having a controllable surface finish. In one form, the ceramic is applied as a coating to a substrate article. Preferably, an aqueous coating mixture of phosphoric acid, alumina powder, and cordierite powder is prepared. The mixture is contacted to the surface of the article, and a mechanical overpressure is applied to the external surface of the mixture using a pressing tool. The surface character of the pressing tool, such as a smooth surface or an intentionally patterned surface, is reproduced on the surface of the final ceramic coating. The coating is heated to a moderate temperature to set the ceramic of the coating, and thereafter the coating is heated to a higher, but still intermediate temperature, to cure the coating.

Cementitious ceramic surface having controllable reflectance and texture

An article is fabricated with a ceramic surface having a controllable surface finish. In one form, the ceramic is applied as a coating to a substrate article. Preferably, an aqueous coating mixture of phosphoric acid, alumina powder, and cordierite powder is prepared. The mixture is contacted to the surface of the article, and a mechanical overpressure is applied to the external surface of the mixture using a pressing tool. The surface character of the pressing tool, such as a smooth surface or an intentionally patterned surface, is reproduced on the surface of the final ceramic coating. The coating is heated to a moderate temperature to set the ceramic of the coating, and thereafter the coating Is heated to a higher, but still intermediate temperature, to cure the coating.

An article has at its surface a nonmetallic ceramic form of a cation reactive with phosphate ion to form a ceramic phosphate, such as an oxide of a cation selected from the group consisting of beryllium, aluminum, iron, magnesium, calcium, thorium, barium, zirconium, zinc, silicon, and mixtures thereof. A source of reactive phosphate ions, such as concentrated phosphoric acid or monoaluminum phosphate, is applied to the surface of the article. The surface of the article is thereafter heated to cause the nonmetallic ceramic form of the cation and the source of the reactive phosphate ions to react together, producing a phosphate-bonded hard layer at the surface of the article.

Surface hardness of articles by reactive phosphate treatment

A consolidation apparatus includes a female mold having a first portion and a second portion, a movable caul plate within the first portion of the female mold, and a pressure bladder disposed between the caul plate and the second portion of the female mold. A pressurization line communicates between the interior of the pressure bladder and a gas source exterior to the female mold, and an evacuation line communicating between the unfilled space between the caul plate and the second portion, and a vacuum source exterior to the female mold. In using the apparatus, a workpiece is loaded into the first portion of the female mold between the caul plate and the first portion. The consolidation apparatus and the workpiece contained therein are heated, a pressure is applied to the pressurization line, and a vacuum is simultaneously applied to the evacuation line.

Method and apparatus for consolidating a workpiece at elevated

An apparatus for consolidating a workpiece includes an oven having a heating cavity and a consolidation press received within the heating cavity of the oven. The consolidation press includes a base, a pressure platen disposed in facing relation to the base, and an expandable bellows operatively connected to the pressure platen to force the pressure platen toward the base. The bellows is expanded by a gas pressure supplied by a pneumatic source. In operation, a workpiece is placed between the base and the platen, and a force is applied to the workpiece by operation of the bellows.

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Poway, CA, United States of America

Robert William Kreutzer