# US 11,027,529 B2 · Joint surface coatings for ceramic components

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- Number: US 11,027,529 B2
- Document ID: US11027529B2
- Status: Granted
- Kind: B2
- Application number: 15/628,148
- Filed: 2017-06-20
- Published: 2017-12-28
- Granted: 2021-06-08
- Earliest claimed: 2016-06-23
- Assignees: ROLLS-ROYCE plc
- Applicants: Rolls-Royce Corporation
- Inventors: Scott Nelson; Sean E. Landwehr; Raymond Ruiwen Xu
- Web page: https://patentgrep.com/patent/US11027529B2

## CPC

- B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products
- B32B 15/04: comprising metal as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042)}
- C04B 35/565: based on silicon carbide
- C04B 37/00: Joining burned ceramic articles with other burned ceramic articles or other articles by heating {(soldering and welding materials B23K35/24; laminated products B32B, E04C)}
- C04B 37/003: {by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts}
- C04B 37/005: {consisting of glass or ceramic material}
- C04B 37/023: {characterised by the interlayer used (C04B37/028 takes precedence)}
- C04B 37/025: {consisting of glass or ceramic material}
- C04B 37/045: {characterised by the interlayer used (C04B37/047 takes precedence)}
- C04B 41/4501: {with preformed sheet-like elements}
- C04B 2235/5244: Silicon carbide
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B 2235/9607: Thermal properties, e.g. thermal expansion coefficient
- C04B 2237/08: Non-oxidic interlayers
- C04B 2237/083: Carbide interlayers, e.g. silicon carbide interlayers
- C04B 2237/12: Metallic interlayers
- C04B 2237/122: based on refractory metals
- C04B 2237/16: Silicon interlayers
- C04B 2237/30: Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B 2237/341: Silica or silicates
- C04B 2237/343: Alumina or aluminates
- C04B 2237/36: Non-oxidic
- C04B 2237/363: Carbon
- C04B 2237/365: Silicon carbide
- C04B 2237/368: Silicon nitride
- C04B 2237/38: Fiber or whisker reinforced
- C04B 2237/52: Pre-treatment of the joining surfaces, e.g. cleaning, machining
- C04B 2237/58: Forming a gradient in composition or in properties across the laminate or the joined articles
- C04B 2237/59: Aspects relating to the structure of the interlayer
- C04B 2237/708: of one or more of the interlayers
- C04B 2237/72: Forming laminates or joined articles comprising at least two interlayers directly next to each other
- C04B 2237/84: Joining of a first substrate with a second substrate at least partially inside the first substrate, where the bonding area is at the inside of the first substrate, e.g. one tube inside another tube
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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

## Abstract

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.

## Claims

### Claim 1

An article comprising:
a component;
a substrate comprising a first ceramic;
a braze or weld layer between the component and the substrate; and
a joint surface coating between the substrate and the braze or weld layer; wherein the joint surface coating comprises:
a first diffusion barrier layer comprising a second ceramic material,
a first compliance layer comprising at least one of a metal or a metalloid, wherein the first compliance layer is a continuous layer on an outer surface of the substrate between the first diffusion barrier layer and the substrate,
a second diffusion barrier layer comprising a third ceramic; and
a second compliance layer comprising at least one of a metal or a metalloid, the second compliance layer being between the first diffusion barrier layer and the second diffusion barrier layer,
wherein the at least one of the metal or the metalloid of the second compliance layer is different than the at least one of the metal or the metalloid of the first compliance layer.

### Claim 2 (depends on 1)

The article of claim 1, wherein the braze or weld layer comprises the braze layer, the braze layer comprising a braze material.

### Claim 3 (depends on 2)

The article of claim 2, wherein the braze material comprises a silicon alloy.

### Claim 4 (depends on 1)

The article of claim 1, wherein the substrate comprises a ceramic matrix composite.

### Claim 5 (depends on 1)

The article of claim 1, wherein the first compliance layer comprises silicon.

### Claim 6 (depends on 1)

The article of claim 1, wherein the first compliance layer consists essentially of silicon.

### Claim 7 (depends on 1)

The article of claim 1, wherein the first diffusion barrier layer comprises silicon carbide.

### Claim 8 (depends on 1)

The article of claim 1, wherein the first diffusion barrier layer consists essentially of silicon carbide.

### Claim 9 (depends on 1)

The article of claim 1, wherein the first diffusion barrier layer is configured to inhibit the diffusion of at least one of SiC, Si3N4, or WC between the substrate and the braze or weld layer.

### Claim 10 (depends on 1)

The article of claim 1, further comprising a braze compatibility layer on the second diffusion barrier layer, wherein the braze compatibility layer comprises at least one of a metal, a metalloid, or a ceramic, wherein the braze compatibility layer is configured to promote wetting of the joint surface coating with a braze material.

### Claim 11 (depends on 10)

The article of claim 10, wherein the braze compatibility layer comprises one or more of Mo, W, Ni, Ti, or SiC.

### Claim 12

A method comprising:
holding a first joining surface of a coated component comprising a substrate adjacent a second joining surface of a second component, wherein the substrate comprises a first ceramic coated with a joint surface coating, wherein the joint surface coating comprises a first diffusion barrier layer, a first compliance layer, a second diffusion barrier layer, and a second compliance layer, wherein the first diffusion barrier layer comprises a second ceramic, wherein the first compliance layer comprises at least one of a metal or a metalloid, wherein the first compliance layer is a continuous layer on an outer surface of the substrate between the first diffusion barrier layer and the substrate, wherein the second compliance layer is between the first diffusion barrier layer and the second diffusion barrier layer;
wherein the second diffusion barrier layer comprising a third ceramic, wherein the second compliance layer comprises at least one of a metal or a metalloid, wherein the at least one of the metal or the metalloid of the second compliance layer is different than the at least one of the metal or the metalloid of the first compliance layer;
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.

### Claim 13 (depends on 1)

The article of claim 1, wherein the first compliance layer has a uniform thickness on the outer surface of the substrate.

### Claim 14 (depends on 13)

The article of claim 13, wherein the first compliance layer is directly on the outer surface of the substrate.

### Claim 15 (depends on 1)

The article of claim 1, wherein the component comprises at least one of a metal substrate, a glass substrate, a polymer substrate, a ceramic substrate or a ceramic matrix composite substrate, and wherein the braze or weld layer is directly adjacent the metal substrate, the glass substrate, the polymer substrate, the ceramic substrate or the ceramic matrix composite substrate.

### Claim 16 (depends on 1)

The article of claim 1, wherein the third ceramic of the second diffusion barrier layer is the same as the second ceramic of the first diffusion barrier layer.