Impurity barrier layer for ceramic matrix composite substrate
AssigneesROLLS-ROYCE plc, Rolls-Royce High Temperature Composites Inc.
InventorsLi Li, Sungbo Shim, Sunny Chang
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Abstract
A method of forming an impurity barrier layer on a CMC substrate may include introducing, to a heated plume of a thermal spray gun, a composite feedstock that includes a first coating material including a plurality of first particles; and a second coating material that may be different from the first coating material, where the second coating material at least partially encapsulates at least a portion of respective surfaces of the plurality of first particles; and directing, using the heated plume, at least the first coating material to a surface of a CMC substrate to deposit an impurity barrier layer including at least the first coating material.
Claims7
A method comprising:
- combining a first coating material comprising a plurality of first particles and a second coating material that is different from the first coating material, wherein the first coating material comprises at least one of silicon carbide or silicon nitride, and wherein the second coating material comprises a pre-ceramic polymer precursor comprising at least one of a silicon carbide based ceramic or a silicon nitride based ceramic;
- blending the first coating material and the second coating material;
- heat-treating the first coating material and the second coating material at between about 450° C. and about 1400° C. to convert the pre-ceramic polymer precursor to a ceramic that at least partially encapsulates respective surfaces of the plurality of first particles to form a composite feedstock;
- introducing, to a heated plume of a thermal spray gun, the composite feedstock
- directing, using the heated plume, at least the first coating material to a surface of a ceramic matrix composite (CMC) substrate to deposit an impurity barrier layer comprising at least the first coating material;
- and
- forming on the impurity barrier layer an overlying layer, wherein the impurity barrier layer is configured to reduce migration of an impurity from the CMC substrate into the overlying layer.
Dependencies are inferred from the claim text.