# US 10,309,018 B2 · Composite article having layer with co-continuous material regions

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- Number: US 10,309,018 B2
- Document ID: US10309018B2
- Status: Granted
- Kind: B2
- Application number: 13/149,027
- Filed: 2011-05-31
- Published: 2012-12-06
- Granted: 2019-06-04
- Earliest claimed: 2011-05-31
- Assignees: United Technologies Corporation
- Applicants: Wayde R. Schmidt; Paul Sheedy
- Inventors: Wayde R. Schmidt; Paul Sheedy
- Web page: https://patentgrep.com/patent/US10309018B2

## CPC

- C23C 28/3215: {at least one MCrAlX layer}
- C04B 41/009: {characterised by the material treated}
- C04B 41/52: Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation}
- C04B 41/89: for obtaining at least two superposed coatings having different compositions
- C23C 28/00: Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C 28/34: {including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates}
- C23C 28/341: {with at least one carbide layer}
- C23C 28/345: {with at least one oxide layer}
- C23C 28/3455: {with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer}
- C23C 28/40: {Coatings including alternating layers following a pattern, a periodic or defined repetition}
- C23C 28/42: {characterized by the composition of the alternating layers}
- C23C 28/44: {characterized by a measurable physical property of the alternating layer or system, e.g. thickness, density, hardness}
- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- F01D 5/284: {Selection of ceramic materials}
- F01D 5/288: {Protective coatings for blades}
- F01D 11/122: {with erodable or abradable material (blades having cutting or grinding tips F01D5/20)}
- F05D 2300/12: Light metals
- F05D 2300/175: Superalloys
- F05D 2300/21: Oxide ceramics
- F05D 2300/22: Non-oxide ceramics
- Y10T 428/12486: Laterally noncoextensive components [e.g., embedded, etc.]
- Y10T 428/24752: Laterally noncoextensive components
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite article includes a substrate, at least one protective layer on the substrate, and an intermediate layer between the protective layer and the substrate. The intermediate layer includes a first material that occupies a first continuous region and a second material that occupies a second continuous region next to the first continuous region. The first continuous region and the second continuous region are each in contact with the substrate and the protective layer.

## Claims

### Claim 1

A composite article comprising:
a substrate formed of a metal alloy or ceramic material;
a protective layer on the substrate, the protective layer formed of a ceramic oxide; and
an intermediate layer between, and in contact with each of, the protective layer and the substrate,
the intermediate layer including a co-continuous microstructure first, second, and third materials of different compositions that occupy, respectively, first, second, and third distinct continuous regions in the co-continuous microstructure, the first, second, and third distinct district continuous regions being continuous with respect to extending continuously from the substrate to the protective layer,
the second distinct continuous region is contiguous with each of the first distinct continuous region and the third distinct continuous region in the co-continuous microstructure and the first distinct continuous region is contiguous with the third distinct continuous region in the co-continuous microstructure,
the first, second, and third distinct continuous regions are each individually amorphous in shape,
and the first material and the substrate have equivalent compositions, the second material and the protective layer have equivalent ceramic oxide compositions, and the third material has a ceramic or metallic composition of different composition than the protective layer and the substrate.

### Claim 2 (depends on 1)

The composite article as recited in claim 1, wherein the first material comprises a first ceramic material and the second material comprises a second, different ceramic material.

### Claim 3 (depends on 1)

The composite article as recited in claim 1, wherein the first material comprises a metallic material and the second material comprises a ceramic material.

### Claim 4 (depends on 1)

The composite article as recited in claim 1, wherein the first material comprises a first metallic material and the third material comprises a different metallic material.

### Claim 5 (depends on 1)

The composite article as recited in claim 1, wherein the first material comprises a first ceramic material, the second material comprises a second, different ceramic material, and the third material comprises a third, different ceramic material.

### Claim 6 (depends on 1)

The composite article as recited in claim 1, wherein the first material comprises a metallic material, the second material comprises a ceramic material and the third material comprises a different ceramic material.

### Claim 7 (depends on 1)

The composite article as recited in claim 1, wherein at least one of the first material, the second material and the third material is hafnia.

### Claim 8 (depends on 1)

The composite article as recited in claim 1, wherein at least one of the first material, the second material and the third material is gadolinia.

### Claim 9 (depends on 1)

The composite article as recited in claim 1, wherein the first material and the substrate are a first ceramic composition, and the second material and the protective layer are a second ceramic composition.