Rolls-royce Corporation

Rolls-royce North American Technologies Inc.

Rolls-royce High Temperature Composites Inc.

Rolls-royce American Technologies, Inc.

Purdue Research Foundation

University of Missouri

Trustees of the Colorado School of Mines

Sean E Landwehr

Ted Joseph Freeman

Adam Lee Chamberlain

Scott Nelson

Aaron D Sippel

Sungbo Shim

Robert J Shinavski

Stephen Isaiah Harris

Raymond Ruiwen Xu

Ann Bolcavage

Thomas Nixon

Donald W Reinhart

Daniel Kent Vetters

Michael Cybulsky

Anthony Martin Goetz

Jeffrey Allen Walston

Bruce Edward Varney

Kang N Lee

Joseph P Lamusga

Li Li

Stephanie Gong

Robert F Proctor

Ngunjoh Lawrence Ndamka

Jacque Sue Bader

Benjamin John Bowin Lai

Quinlan Yee Shuck

Matthew R Gold

Jeffrey Paul Youngblood

Todd Engel

Gregory Eugene Hilmas

Andrew J Ritchey

William Gene Fahrenholtz

William Westphal

Rodney W Trice

Juan Carlos Madeni

Jeremy Lee Watts

Kenneth A Green

Stephen Liu

Juan Wei

Robert Golden

Samantha Tatar

Derek Scott King

Joel Davis

Nasrin Al Nasiri

William Edward Lee

In some examples, an article may include a substrate and a coating system on the substrate. The coating system may include a layer comprising a plurality of voids, wherein respective voids of the plurality of voids define respective void volumes; and a nucleating agent within at least some of the respective void volumes of the layer, wherein the nucleating agent is configured to induce crystallization of the molten CMAS. The coating system may include an environmental barrier coating, thermal barrier coating, and/or abradable coating.

Coating system including nucleating agent

A method includes predicting a composition of calcium-magnesium-aluminum-silicate (CMAS) to be encountered by a high temperature mechanical system during use of the high temperature mechanical system. The method further includes selecting a composition of a CMAS-resistant barrier coating layer based at least in part on the predicted composition of CMAS. The CMAS-resistant barrier coating layer includes a base composition and at least one secondary oxide selected based on the predicted composition of CMAS. The at least one secondary oxide includes at least one of an oxide of a divalent element, an oxide of a trivalent element, or an oxide of a tetravalent element. The CMAS-resistant barrier coating layer comprises greater than 0 mol. % and less than about 7 mol. % of the at least one secondary oxide.

CMAS-resistant barrier coatings

A system and method for forming a porous ceramic preform is provided. The method may include forming a stacked powder structure including a binder layer and a powder layer on the binder layer. The binder layer may be formed by depositing a binder with a spray nozzle on a substrate. The powder layer may be formed by depositing a powder on the binder layer. The porous ceramic preform may be formed by heating the stacked powder structure to pyrolyze the binder. The porous ceramic preform is configured to be infiltrated by a molten material. The substrate may comprise a ceramic fiber preform. After melt infiltration of the porous ceramic preform and the ceramic fiber preform, a densified ceramic feature having a predetermined geometry may be formed on a ceramic matrix composite (CMC) component.

Additive layer method for application of slurry-based features

A system and method for forming a ceramic matrix composite blade track is provided. The method may include stacking a plurality of first plies to form a first porous preform layer, the first plies including a plurality of first ceramic fibers. The method may further include stacking a plurality of second plies to form a second porous preform layer, the second plies including a plurality of second ceramic fibers. The method may further include combining the first porous preform layer and the second porous preform layer to form a unified porous preform. The method may further include forming a structural layer by infiltrating the first porous preform with a first ceramic matrix material, and forming an abradable layer by infiltrating the second porous preform with a second ceramic matrix material.

CMC blade track with integral abradable

In some examples, techniques of repairing and/or reinforcing oxide-oxide ceramic matrix composite (CMC) materials using a metallic material. In one example, a method including applying a metallic material at an edge of an oxide-oxide CMC substrate; and heating the metallic material to diffuse the metal material into the oxide-oxide CMC substrate at the edge. In another example, a method including applying a metallic material onto a damaged area of the oxide-oxide CMC; applying a reinforcing phase material onto the damaged area of the oxide-oxide CMC; and heating the metallic material to diffuse the metallic material into the oxide-oxide CMC and attach the reinforcing phase material to the damaged area of the oxide-oxide CMC.

Repair and/or reinforcement of oxide-oxide CMC

An assembly for a gas turbine engine includes ceramic material containing (i.e. ceramic matrix composite) segments and joints that couple the segments together.

Ceramic matrix composite joints

In some examples, a braze material includes a first set of particles, a second set of particles, and a polymeric binder. The first set of particles includes a braze powder, where the braze powder comprises an Si-containing alloy. The first set of particles defines an average or median particle diameter between about 1 &#x3bc;m and about 40 &#x3bc;m. The second set of particles includes at least one of SiC or a transition metal carbide, where the second set of particles has a multimodal particle size distribution.

Braze material for ceramic matrix composite articles

The disclosure describes techniques for joining a first part including a ceramic or a CMC and a second part including a ceramic or a CMC using brazing. A technique may include positioning a filler material in a joint region between the first and second parts and a metal or alloy on a bulk surface of the filler material. The metal or alloy may be locally heated to melt the metal or alloy, which may infiltrate the filler material. A constituent of the molten metal or alloy may react with a constituent of the filler material to join the first and second parts. Another technique may include depositing a powder that includes the filler material and the metal or alloy in the joint region. Substantially simultaneously with depositing the powder, the powder may be locally heated. A constituent of the molten metal or alloy may react with a constituent of the filler material to join the first and second parts.

Braze for ceramic and ceramic matrix composite components

An example article may include a component, a substrate including a first ceramic, a joining layer between the component and the substrate, and a joint surface coating between the substrate and the joining layer. The joint surface coating may include a diffusion barrier layer including a second ceramic material, and a compliance layer including at least one of a metal or a metalloid. An example technique may include holding a first joining surface of a coated component adjacent a second joining surface of a second component. The example technique may further include heating at least one of the coated component, the second component, and a braze material, and brazing the coated component by allowing the braze material to flow in a region between the first joining surface and the second joining surface.

Joint surface coatings for ceramic components

A braze alloy for joining or repairing ceramic matrix composite (CMC) components comprises a braze composition including silicon at a concentration from about 48 at. % to about 66 at. %, titanium at a concentration from about 1 at. % to about 35 at. %, and an additional element selected from aluminum, cobalt, vanadium, nickel, and chromium. The braze composition comprises a melting temperature of less than 1300&#xb0; C.

Braze alloys for joining or repairing ceramic matrix composite (CMC) components

A method of preparing a ceramic matrix composite (CMC) component that includes a protective ceramic layer comprises adhering at least one flexible ceramic tape to a ceramic fiber preform, where the at least one flexible ceramic tape comprises ceramic particles dispersed in an organic binder phase. After the adhering, the at least one flexible ceramic tape is heated to a temperature sufficient to volatilize the organic binder phase, thereby forming a porous ceramic layer on at least a portion of the ceramic fiber preform. After the heating and volatilizing, the ceramic fiber preform and the porous ceramic layer are infiltrated with a molten material, thereby forming a CMC component including, on at least a portion thereof, a protective ceramic layer.

Method of making a ceramic matrix composite (CMC) component including a protective ceramic layer

A method of forming a composite article includes impregnating an inorganic fiber preform with a slurry composition. The slurry composition includes a particulate, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to immobilize the particulate and yield a gelled article, and substantially all solvent is removed from the gelled article to form a green composite article. The green composite article is then infiltrated with a molten infiltrant to form the composite article.

Method for making ceramic matrix composite articles

One aspect of the present disclosure includes a turbine vane assembly comprising a vane made from ceramic matrix composite material having an outer wall extending between a leading edge and a trailing edge and between a first end and an opposing second end; an endwall made at least partially from a ceramic matrix composite material configured to engage the first end of the vane; and a retaining region including corresponding bi-cast grooves formed adjacent the first end of the vane and a receiving aperture formed in the endwall; wherein a bond is formed in the retaining region to join the vane and endwall together.

Method of assembly of bi-cast turbine vane

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, method including forming an EBC layer on a substrate, wherein the EBC layer exhibits an initial porosity; forming a layer of silicate glass on a surface of the EBC layer; and melting the silicate glass on the surface of the EBC layer to infiltrate the EBC layer with the molten silicate glass to decrease the porosity of the EBC layer from the initial porosity to a final porosity.

Dense environmental barrier coatings

Growing community of inventors

Avon, IN, United States of America

Sean E Landwehr