High temperature brazing of metals and ceramics to carbon substrates
AssigneeHoneywell International Inc.
InventorsMehrad Mehr, Bahram Jadidian
Life of this patent
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Abstract
An apparatus includes a first component comprising a carbon composite substrate. A high temperature coating is disposed on the surface of the carbon composite substrate. The high temperature coating includes a bond layer of a metal carbide on the surface of the substrate. The apparatus includes a second component, and braze material joining the surface of the first component to the second component. In some examples, a brake assembly may include a rotor having a surface configured to interface with another component of the brake assembly. The brake assembly includes an insert joined to the surface of the rotor without a mechanical fastener, and the insert defines a tough mechanical contact surface configured to protect the rotor.
Claims20
An article comprising:
- a first component comprising:
- a substrate comprising a carbon matrix;
- and
- a high temperature coating on a surface of the substrate, wherein the high temperature coating comprises a bond layer of a metal carbide on the surface of the substrate formed from and integrated with the surface of the substrate, wherein the bond layer extends into and substantially fills surface voids of the carbon matrix to form a substantially continuous coating formed in situ from the substrate, and wherein the bond layer comprises a metal-rich metal carbide having a stoichiometrically greater amount of metal than carbon;
- a second component comprising a carbon substrate, a carbon/carbon composite substrate, or a monolithic ceramic substrate;
- and
- a layer of braze material joining a surface of the high temperature coating of the first component to a surface of the second component.
An article comprising:
- a first component comprising:
- a substrate comprising a carbon/carbon composite;
- and
- a high temperature coating on a surface of the substrate, wherein the high temperature coating comprises a bond layer of silicon carbide on the surface of the substrate, and wherein a thickness of the high temperature coating is between 1 micrometer and 30 micrometers, wherein the thickness of the high temperature coating is formed by converting a surface portion of the substrate from carbon to the silicon carbide, and wherein the surface portion of the substrate has a thickness of between 1 micrometer and 30 micrometers, and wherein the bond layer extends into and substantially fills surface voids of a carbon matrix of the carbon/carbon composite to form a substantially continuous coating formed in situ from the substrate;
- a second component comprising a monolithic ceramic substrate of ytterbium disilicate;
- and
- a braze material joining a surface of the high temperature coating of the first component to a surface of the second component, the braze material defining a layer with a thickness between 0.5 millimeters and 20 millimeters, and the braze material comprises a platinum group metal.
A method comprising:
- forming a high temperature coating on a surface of a substrate of a first component, wherein the first component comprises a substrate comprising a carbon matrix, and wherein forming the high temperature coating comprises forming a bond layer of a metal carbide on the surface of the substrate by converting a surface portion of the substrate from carbon to the metal carbide, wherein the bond layer extends into and substantially fills surface voids of the carbon matrix to form a substantially continuous coating formed in situ from the substrate;
- and
- joining a surface of a second component to a surface of the high temperature coating of the first component by brazing with a layer of braze material, wherein the second component comprises a carbon substrate, a carbon/carbon composite substrate, or a monolithic ceramic substrate.
Dependencies are inferred from the claim text.