The patent badge is an abbreviated version of the USPTO patent document. The patent badge does contain a link to the full patent document.

The patent badge is an abbreviated version of the USPTO patent document. The patent badge covers the following: Patent number, Date patent was issued, Date patent was filed, Title of the patent, Applicant, Inventor, Assignee, Attorney firm, Primary examiner, Assistant examiner, CPCs, and Abstract. The patent badge does contain a link to the full patent document (in Adobe Acrobat format, aka pdf). To download or print any patent click here.

Date of Patent:
Nov. 17, 2015

Filed:

Jan. 10, 2012
Applicants:

Gary B. Merrill, Orlando, FL (US);

Cora Schillig, Orlando, FL (US);

Inventors:

Gary B. Merrill, Orlando, FL (US);

Cora Schillig, Orlando, FL (US);

Assignee:
Attorney:
Primary Examiner:
Int. Cl.
CPC ...
B32B 7/02 (2006.01); B32B 5/30 (2006.01); B32B 3/00 (2006.01); C04B 37/02 (2006.01); B22F 3/105 (2006.01); B22F 5/00 (2006.01); B22F 7/00 (2006.01); B82Y 30/00 (2011.01); B32B 3/26 (2006.01); B22F 3/10 (2006.01); B22F 3/11 (2006.01);
U.S. Cl.
CPC ...
B32B 7/02 (2013.01); B22F 3/105 (2013.01); B22F 5/009 (2013.01); B22F 7/002 (2013.01); B32B 3/26 (2013.01); B32B 5/30 (2013.01); B82Y 30/00 (2013.01); C04B 37/021 (2013.01); B22F 3/1017 (2013.01); B22F 3/1112 (2013.01); B32B 2264/105 (2013.01); B32B 2264/107 (2013.01); B32B 2307/304 (2013.01); C04B 2235/34 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/5454 (2013.01); C04B 2235/5472 (2013.01); C04B 2235/666 (2013.01); C04B 2235/9607 (2013.01); C04B 2237/343 (2013.01); C04B 2237/348 (2013.01); C04B 2237/403 (2013.01); C04B 2237/405 (2013.01); C04B 2237/64 (2013.01); C04B 2237/704 (2013.01); Y10T 428/24496 (2015.01); Y10T 428/24942 (2015.01); Y10T 428/249969 (2015.04);
Abstract

A powder-based material system having an intrinsic and stable degree of porosity provided by hollow ceramic spheres () in a fully dense matrix (). A substrate () is formed from a metal powder (), and may be partially sintered (). A layer () of ceramic powder is arranged on the substrate including the pre-sintered hollow ceramic spheres plus a proportion of nano-sized ceramic particles effective to reduce the layer sintering temperature and to increase the sintering shrinkage of the layer to approximate that of the metal substrate during subsequent co-sintering. The substrate and layer are then co-sintered (), such as with spark plasma sintering (), at a temperature and for a duration to fully densify the ceramic powder matrix around the hollow spheres, thereby producing a metal/ceramic material system with low interface stress and with stable porosity during operational temperatures in a gas turbine engine.


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