US3773549A - Ceramic coated porous metal structure and process therefor - Google Patents
Ceramic coated porous metal structure and process therefor Download PDFInfo
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- US3773549A US3773549A US00203364A US3773549DA US3773549A US 3773549 A US3773549 A US 3773549A US 00203364 A US00203364 A US 00203364A US 3773549D A US3773549D A US 3773549DA US 3773549 A US3773549 A US 3773549A
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- porous metal
- ceramic
- metal structure
- containing material
- coating
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 80
- 239000002184 metal Substances 0.000 title claims abstract description 80
- 238000000034 method Methods 0.000 title claims abstract description 41
- 239000000919 ceramic Substances 0.000 title claims description 54
- 238000000576 coating method Methods 0.000 claims abstract description 38
- 239000011248 coating agent Substances 0.000 claims abstract description 35
- 230000003647 oxidation Effects 0.000 claims abstract description 35
- 238000007254 oxidation reaction Methods 0.000 claims abstract description 35
- 239000011148 porous material Substances 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims description 91
- 239000007788 liquid Substances 0.000 claims description 24
- 239000000725 suspension Substances 0.000 claims description 21
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 claims description 18
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 8
- FGIUAXJPYTZDNR-UHFFFAOYSA-N potassium nitrate Chemical compound [K+].[O-][N+]([O-])=O FGIUAXJPYTZDNR-UHFFFAOYSA-N 0.000 claims description 8
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 claims description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 5
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 5
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 claims description 4
- 238000005524 ceramic coating Methods 0.000 claims description 4
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- 239000010941 cobalt Substances 0.000 claims description 4
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- 239000007789 gas Substances 0.000 claims description 4
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- 235000010333 potassium nitrate Nutrition 0.000 claims description 4
- 239000004323 potassium nitrate Substances 0.000 claims description 4
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 4
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 3
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 claims description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
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- 230000004888 barrier function Effects 0.000 claims description 3
- 229910052790 beryllium Inorganic materials 0.000 claims description 3
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 claims description 3
- -1 borides Chemical class 0.000 claims description 3
- 229910052810 boron oxide Inorganic materials 0.000 claims description 3
- 229910052792 caesium Inorganic materials 0.000 claims description 3
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical compound [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 claims description 3
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052735 hafnium Inorganic materials 0.000 claims description 3
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims description 3
- 239000003350 kerosene Substances 0.000 claims description 3
- 229910052744 lithium Inorganic materials 0.000 claims description 3
- 229910052749 magnesium Inorganic materials 0.000 claims description 3
- 239000011777 magnesium Substances 0.000 claims description 3
- 150000001247 metal acetylides Chemical class 0.000 claims description 3
- 239000007769 metal material Substances 0.000 claims description 3
- 229910052750 molybdenum Inorganic materials 0.000 claims description 3
- 239000011733 molybdenum Substances 0.000 claims description 3
- 150000004767 nitrides Chemical class 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 3
- 229910021332 silicide Inorganic materials 0.000 claims description 3
- 235000012239 silicon dioxide Nutrition 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 229910052708 sodium Inorganic materials 0.000 claims description 3
- 239000011734 sodium Substances 0.000 claims description 3
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 3
- 229910001948 sodium oxide Inorganic materials 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- 229910010293 ceramic material Inorganic materials 0.000 abstract description 2
- 239000000203 mixture Substances 0.000 description 10
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
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- 229910001092 metal group alloy Inorganic materials 0.000 description 4
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- 239000002245 particle Substances 0.000 description 4
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- 231100000241 scar Toxicity 0.000 description 4
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- 239000011651 chromium Substances 0.000 description 3
- 230000001627 detrimental effect Effects 0.000 description 3
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- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 230000002902 bimodal effect Effects 0.000 description 2
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- 238000001035 drying Methods 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 238000004663 powder metallurgy Methods 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 101100536354 Drosophila melanogaster tant gene Proteins 0.000 description 1
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- 241000334993 Parma Species 0.000 description 1
- WAIPAZQMEIHHTJ-UHFFFAOYSA-N [Cr].[Co] Chemical compound [Cr].[Co] WAIPAZQMEIHHTJ-UHFFFAOYSA-N 0.000 description 1
- 239000011358 absorbing material Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
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- 238000005056 compaction Methods 0.000 description 1
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- 238000012937 correction Methods 0.000 description 1
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- 239000002241 glass-ceramic Substances 0.000 description 1
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- 229910000856 hastalloy Inorganic materials 0.000 description 1
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- 239000000314 lubricant Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
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- 229920000136 polysorbate Polymers 0.000 description 1
- 230000003449 preventive effect Effects 0.000 description 1
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Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- 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
- C23C24/00—Coating starting from inorganic powder
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
- C23F15/00—Other methods of preventing corrosion or incrustation
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
Definitions
- Porous metal structures such as porous sheets, are admirably suited for use in such applications as filters, abradable seals, sound suppression structures, bearings and bearing retainers, energy absorbing material and the like.
- One disadvantage of porous structures is that the metal component of the structure, while being relatively oxidation resistant when present in the bulk state in the temperature range of up to lOC, is subject to oxidation when fabricated into a porous state because of its fine structure and extensive surface area.
- porous metal structures are somewhat limited in their applications to uses wherein they will not be exposed to high temperature oxidizing environments.
- Abradable seals and bearing materials which are designed for aerospace applications or the like are intended to 'be subjected to oxidation environments thus curtailing their useful and functional life.
- One of the primary objectives 'of this invention is' to provide an oxidation resistant coating for porous metal structures composed of a ceramic-containing material which will not adversely affect the abradability of porous metal structures when intended for abradable seal applications and will extend the maximum oxidation protection temperature of porous structures intended for bearing applications.
- the invention relates to an oxidation resistant ceramic-containing coating for porous metal structures that will not substantially affect the abradability of such structures when intended for abradable seal application usage, nor substantially affect the characteristics required of porous structures intended for bearing application or filter usage.
- the process for applying an oxidation resistant ceramic coating on a porous metal structure would initially entail preparing a colloidal-like suspension of a finely ground ceramic-containing material in a liquid suspending vehicle.
- the colloidal-like suspension can then be deposited on a porous metal structure to be coated, after which the coated structure is dried to substantially remove the liquid suspending vehicle thereby leaving a dispersed deposition of the ceramiccontaining material on the walls of the accessible pores throughout the structure.
- the ceramiccontaining material dispersed on the porous metal structure is heated to a temperature below the melting point of the metal components of the porous metal structure, but sufficient to cause the ceramiccontaining material to fuse and wet the wall surfaces of the pores in the structure.
- the porous metal structure will have a ceramic coating which will act as a barrier so as to minimize attack of foreign gases, such as oxygen, on the metal.
- a ceramiccontaining coating on porous structures usually between about 0.01 micron and about 10 microns thick and preferably between about 0.01 micron and about 5 microns thick would be admirably suited for abradable seal applications.
- a ceramic-containing coating on porous structures between about 1 micron and about 30 microns would be suitable.
- the exact coating thickness on a porous metal structure for a particular application can be determined by any artisan, familiar with porous materials, using the process of this invention.
- Colloidal-like suspension is intended to mean a suspension of finely ground particles wherein said particles are substantially uniformly dispersed throughout the suspending liquid and are sized to less than 10 micron particle size.
- a porous metal structure having a nominal pore size of l00 microns or less can be fabricated by known techniques using any metal or metal alloy that is available in powdered, flaked, or fibrous-form and that can be sintered with substantially uniformly controlled pore sizes ranging anywhere from submicronic to 100 microns and higher.
- alloy compositions suitable for porous metal abradable'seals include such alics, glass and glass ceramics, in any and all proportions and combinationsjCeramics are basically a class of inorganic, nonmetallic substances as opposed to organic or metallic substances.
- a suitable ceramic-containing material can be selected as the coating material.
- a suitable ceramic-containing material could be selected from at least one material selected from the group consisting of silicon dioxide, chromium oxide, titanium oxide, aluminum oxide, boron oxide, sodium oxide, and potassium nitrate.
- various other ceramic groups can be used such as the oxides, carbides, borides, nitrides, and silicides of such materials as aluminum, magnesium, sodium, lithium, beryllium, cesium, titanium, zirconium, hafnium, tungsten, molybdenum, iron, cobalt, and the like.
- a preferred method of coating porous metal structures is to first pulverize the ceramic-containing material and then suspend it in a liquid suspending vehicle to form a colloidal-like suspension.
- the liquid suspending vehicle with the substantially dispersed ceramiccontaining material can then be deposited on the surface of a porous structure by any conventional technique such as painting, spraying, rolling, or dipping the structure into the colloidal-like suspension.
- the technique for depositing the colloidal-like suspension on and in the porous structure should be adequate so that a layer of the solution is applied to the surface of the porous structure including the internal walls of accessible pores.
- the coated porous metal structure can be slightly heated, or dried at room temperature, so as to substantially remove the liquid suspending vehicle from the ceramic-containing material so that the latter will be left adhering to the surface of the porous structure. Thereafter, the structure is subjected to a heated environment at a temperature sufficient to cause the ceramic-containing material to assume a molten state whereupon it will fuse and wet the surface of the porous structure providing the substantially uniform layer thereon.
- the walls of the internal pores will be substantially protected against the penetration of foreign gases, such as oxygen.
- the ceramic-containing coating which can be deposited as a thin layer on a porous metal structure, it is necessary to initially pulverize the ceramic-containing material to a size smaller than about microns and preferably less than about 1 micron. It is to be understood that the exact size of the pulverized ceramic-containing material is somewhat dependent on the pore size of the porous metal structure to be coated. Thus, when coating a porous metal structure having a nominal pore size of about 100 microns, it will be desirable to pulverize the ceramiccontaining material to less than about 10 microns, while coating a porous metal structure with a nominal pore size of 10 microns will preferably require the ceramic-containing material to be pulverized to less than about 1 micron.
- the purpose for pulverizing the ceramic-containing material to a fine fraction is to enable the material to be deposited within the walls of accessible pores in the porous metal structure without substantially plugging the pores.
- the liquid suspending vehicle can be any liquid capable of suspending the selected pulverized ceramic containing material in a substantially uniformly dispersed manner and which is capable of wetting the metal or metal alloy of the porous structure.
- the liquid suspending vehicle is added in a sufficient amount to form a slurry with the pulverized ceramic-containing material so that when the colloidal-like suspension is deposited on and in the porous metal structures, it will be substantially removed from the porous metal structure thereby leaving the pulverized ceramic-containing material dispersed on the wall surfaces of the accessible pores in the porous metal structure. It is recommended that the viscosity of the colloidal-like suspension be about centipoises or less and preferably about 10 centipoises.
- Suitable liquid suspending vehicles are alcohol, alcohol containing liquids, methanol, acetone, heptane, and kerosene.
- a preferred embodiment of this invention would be to select a ceramic-containing material which has a softening range rather than a melting temperature, such softening temperature range being the preferred operating temperature of the coated porous metal structure.
- glass type ceramics are admirably suited for use in this invention and preferably those materials having a soft or molten state at temperatures between about l600F and 2300F.
- the ceramiccontaining material having good oxidation resistant properties is selected, it is finely pulverized and suspended in a slurry or colloidal-like suspension which will wet and fill the pores of the porous structure.
- ceramic-containing materials can be pulverized to a submicron particle size in a liquid suspending vehicle using nickel base alloy balls in a nickel based alloy container so as to minimize contamination.
- the mixture can be ball milled for a time sufficient to cause the resulting mixture to approach a colloidal suspension, that being evidenced by no visible separation of the ceramic-containing material in the liquid.
- the colloidal-like suspension can then be diluted with a liquid suspending vehicle, preferably the same used in the mill operation, to obtain a viscosity of between about 100 centipoises and about 1 centipoise and preferably about 10 centipoises.
- the viscosity of the colloidal-like suspension can be varied depending on the porous metal structure to be coated.
- the colloid coated porous structure is then exposed to ambient so as to evaporate substantially all of the liquid suspending vehicle thereby leaving the ceramic-containing material substantially uniformly disposed on the wall surface of the pores in the structure.
- the ceramic-containing coated porous structure is then heated to the molten state temperature of the ceramic-containing material whereupon the ceramic-containing material substantially fuses and wets the wall surfaces of the accessible pores in the porous structure thus forming a thin protective coating on and within the structure.
- Ceramiccontainin'g materials having a softening range between about l600F and 2300F should be heated to between about 1800F and 2400F. As stated above, this temperature should be below the melting temperature of the metal components in the porous metal structure.
- the coated porous structure is thereafter cooled and ready for its intended application.
- a ceramic-containing material having good oxidation resistant properties at between about 1200F and about 2000F and being soft or molten at temperatures between 1600F and 2000F is ideally suited. It is to be understood that the ceramiccontaining material selected has to be compatible with the metal components of the porous metal structure so that detrimental reactions do not occur. Ceramic mixtures containing SiO Cr O A1 and TiO are admirably suited for this purpose.
- the above process can be repeated so in effect we have a multiple layer build-up which upon being heated in the final stage will form a substantially homogeneous coating.
- EXAMPLE 1 A porous metal abradable seal, commercially available as Type AB-l measuring 2 inches by 6 inches and being 0.06 inch thick on an lnconel 600 backing sheet (0.06 inch thick) was obtained from Union Carbide Corporation.
- This commercial abradable seal fabricated by a diffusion-sintered bonding ofNi alloy (nominal 80% Ni-20% Cr) as disclosed in U. S. copending application Ser. No. 128,182, had a void fraction of 0.65 nominal, a bulk density of 3 grams per cubic centimeter, a tensile strength of 500 pounds per square inch nominal, and a hardness of 91 nominal based on a Rockwell B scale of inch diameter ball at a 15 kilogram load.
- the abradable seal material was coated with a ceramic mix (cermet) of the following composition:
- frit 100 grams of frit (commercially available as No. 6210 from the Ferro Composition, Cleveland, Ohio).
- the abradable seal material was then impregnated with the solution which was applied by a roller technique.
- the coated abradable seal material was allowed to dry at room temperature for about 8 hours after which it was furnaced in a continuous belt furnace at 1 150C for a period of 30 minutes in a hydrogen atmosphere.
- the coating material which was applied to the abradable seal material amounted to 0.8 percent of the weight of the coated material.
- the coated abradable seal material was then subjected to an oxidation environment within a furnace at a temperature of 1600F.
- the percent weight gained after various exposure times is indicated as Curve 1' on the graph of the drawing.
- a similar abradable seal material, except lacking the coating of this invention, was also subjected to the same oxidation environment and showed a substantial weight increase over that of the coated abradable seal for similar time periods.
- Curve 1 on the graph represents the uncoated abradable seal material.
- a comparison of Curves 1 and l demonstratively reveals the increase in the oxidation resistant characteristics of a porous metal structure coated in accordance with this invention.
- the coated and uncoated abradable seal materials specified above were subjected to an abradability test utilizing a tester composed of a 7% inch diameter rotating knife edge having a peripheral speed of revolutions per second and designed to plunge at a depth of 0.001 inch per second until a scar ofa 0.030 inch depth was imparted in the material being tested.
- the horsepower required to produce this 0.030 inch scar in both the coated and uncoated materials was compared and found to be essentially the same, that being about 0.1 of a horsepower.
- This abradability test was conducted on the materials both before and after the materials were subjected to the oxidation environment. Thus, the ceramic oxidation coating on the abradable seal material produced no detrimental effects to the abradability characteristics of the material.
- EXAMPLE 2 Abradable seal material similar to that as in Example 1 except that it had a hardness of 85 nominal as measured by a Rockwell B scale with a 54 inch diameter ball under a 15 kilogram load. This material was also fabri cated as disclosed in U. S. copending application Serial No. 128,182 and was commercially obtained from Union Carbide Corporation as Type AB-2 abradable seal material. The abradable seal material measured 2 inches by 6 inches and was 0.06 inch thick on an lnconel 600 backing sheet (0.06 inch thick).
- Example 2 A ceramic mix identical to that specified in Example 1 was applied to the abradable seal material as also disclosed in Example 1.
- the coated abradable seal material was then allowed to dry at room temperature for about 8 hours after which it was subjected to a hydrogen atmosphere in a heated environment of a continuous belt furnace at a temperature of 1 C for a period of 30 minutes.
- the coating material which was added to the abradable seal material amounted to 0.8 percent of the weight of the coated material.
- the coated abradable seal material was then subjected to an oxidation environment within a furnace at a temperature of 1600F.
- the percent weight gained after various exposure times is indicated as Curve 11' on the graph of the drawing.
- a similar abradable seal material, except lacking the coating of this invention, was also subjected to the same oxidation environment and showed a substantial weight increase over that of the coated abradable seal for similar time periods.
- Curve 1 1 on the graph of the drawing represents the uncoated abradable seal material.
- a comparison of Curves 11 and 11 demonstratively reveals the increase in the oxidation resistant characteristics of a porous metal structure coated in accordance with this invention.
- the coated and uncoated abradable seal materials specified above were subjected to an abradability test utilizing a tester composed of a 7% inch diameter rotating knife edge having a peripheral speed of 100 revolutions per second and designed to plunge at a depth of 0.00] inch per second until a scar ofa 0.030 inch depth was imparted in the material being tested.
- the horsepower required to produce this 0.030 inch scar in both the coated and uncoated materials was compared and found to be essentially the same, that being below 0.1 of a horsepower.
- This abradability test was conducted on the materials both before and after the materials were subjected to the oxidation environment. Thus, the ceramic oxidation coating on the abradable seal material produced no detrimental effects to the abradability characteristics of the material.
- the oxidation resistant coating of this invention is also admirably suited for use on porous metal structures having a bimodal pore distribution, that is, a porous structure having two nominal pore sizes.
- the colloidal-like suspension of ceramic-containing material could be deposited on the structure in a state that would permit the smaller pores to be filled with the coating by capillary action. After drying, the bimodal porous structure would be heated so that the ceramiccontaining material would substantially fuse and wet the walls of the larger pores while substantially filling the cavities of the smaller pores. This would provide the porous structure with a good oxidation resistant coating while not substantially affecting the mechanical properties of the structure.
- a process for coating porous metal structures having a nominal pore size no greater than 100 microns with an oxidation resistant ceramic-containing material comprising the steps:
- step (a) depositing a layer of the colloidal-like suspension of step (a) on the surface of the porous metal structure;
- step (c) said liquid suspending vehicle is substantially removed at room temperature.
- step (a) said ceramic-containing material is selected from at least one of the groups consisting of oxides, carbides, borides, nitrides, and silicides of aluminum, magnesium, sodium, lithium, beryllium, cesium, titanium, zirconium, hafnium, tungsten, molybdenum, iron and cobalt.
- step (a) said ceramic-containing material is selected from at least one of the groups consisting of silicon dioxide, chromium oxide, titanium oxide, aluminum oxide, boron oxide, sodium oxide, and potassium nitrate.
- step (a) said ceramic-containing material has a softening range at a temperature between about 1600F and about 2300F; and wherein in step (d) said porous metal material is heated to a temperature between about 1800F and about 2400F.
- step (a) said finely ground ceramic-containing material is sized be tween about 0.01 micron and about 10 microns.
- step (a) said liquid suspending vehicle is selected from at least one of the groups consisting of alcohol, an alcoholcontaining liquid, methanol, acetone, heptane, and kerosene.
- step (a) has a viscosity of between about centipoises and about 1 centipoise.
- step (d) said layer of ceramic coating material is between about 0.01 micron and about 10 microns.
- step (d) said ceramic-containing material is between about 1 micron and about 30 microns thick.
- a porous metal structure having a nominal pore size no greater than 100 microns and having an oxidation resistant coating of a ceramic-containing material, said coating being deposited substantially on the wall surfaces of the pores in said porous metal structure thereby providing a barrier which substantially minimizes the attack of gases on the metal.
- porous metal structure of claim 13 intended for abradable seal applications wherein said oxidation resistant coating is between about 0.01 micron and about 10 microns thick.
- porous metal structure of claim 13 intended for bearing application wherein said oxidation resistant coating is between about 1 micron and about 30 microns thick.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Chemically Coating (AREA)
- Powder Metallurgy (AREA)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US20336471A | 1971-11-30 | 1971-11-30 |
Publications (1)
Publication Number | Publication Date |
---|---|
US3773549A true US3773549A (en) | 1973-11-20 |
Family
ID=22753679
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US00203364A Expired - Lifetime US3773549A (en) | 1971-11-30 | 1971-11-30 | Ceramic coated porous metal structure and process therefor |
Country Status (6)
Country | Link |
---|---|
US (1) | US3773549A (enrdf_load_stackoverflow) |
JP (1) | JPS4864107A (enrdf_load_stackoverflow) |
BE (1) | BE792075A (enrdf_load_stackoverflow) |
CA (1) | CA981992A (enrdf_load_stackoverflow) |
FR (1) | FR2162082B1 (enrdf_load_stackoverflow) |
GB (1) | GB1414519A (enrdf_load_stackoverflow) |
Cited By (24)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3922458A (en) * | 1972-11-24 | 1975-11-25 | Curran Oils Ltd | Vitreous enamelling |
US3963502A (en) * | 1973-02-02 | 1976-06-15 | P. R. Mallory & Co., Inc. | Composition for application to die cavity surface |
US4059712A (en) * | 1976-01-26 | 1977-11-22 | Bothwell Bruce E | Metal-ceramic composite and method for making same |
US4059707A (en) * | 1975-08-29 | 1977-11-22 | Rca Corporation | Method of filling apertures with crystalline material |
US4251272A (en) * | 1978-12-26 | 1981-02-17 | Union Carbide Corporation | Oxidation resistant porous abradable seal member for high temperature service |
US4276331A (en) * | 1976-01-26 | 1981-06-30 | Repwell Associates, Inc. | Metal-ceramic composite and method for making same |
US4425411A (en) | 1981-05-21 | 1984-01-10 | Swiss Aluminium Ltd. | Mold with thermally insulating, protective coating |
US4427721A (en) | 1977-11-01 | 1984-01-24 | United Kingdom Atomic Energy Authority | Method of coating steel substrates to reduce carbonaceous deposition thereon |
US4713300A (en) * | 1985-12-13 | 1987-12-15 | Minnesota Mining And Manufacturing Company | Graded refractory cermet article |
US4738874A (en) * | 1984-12-28 | 1988-04-19 | Commissariat A L'energie Atomique | Process for the production of porous, permeable mineral membranes |
WO1989011342A1 (en) * | 1988-05-24 | 1989-11-30 | Ceramem Corporation | Porous inorganic membrane with reactive inorganic binder, and method of forming same |
US5364586A (en) * | 1993-08-17 | 1994-11-15 | Ultram International L.L.C. | Process for the production of porous membranes |
US5996497A (en) * | 1998-06-12 | 1999-12-07 | Eastman Kodak Company | Method of making a durable hydrophilic layer |
WO2000073530A1 (en) * | 1999-05-27 | 2000-12-07 | Sandvik Ab; (Publ) | Surface modification of high temperature alloys |
AU775455B2 (en) * | 1999-05-27 | 2004-08-05 | Sandvik Intellectual Property Ab | Surface modification of high temperature alloys |
US20040253371A1 (en) * | 2003-06-10 | 2004-12-16 | Janney Mark A. | Filter and method of fabricating |
US20060057295A1 (en) * | 1999-07-31 | 2006-03-16 | The Regents Of The University Of California | Structures and fabrication techniques for solid state electrochemical devices |
WO2008046785A2 (de) | 2006-10-17 | 2008-04-24 | Robert Bosch Gmbh | Verfahren zur stabilisierung und funktionalisierung von porösen metallischen schichten |
US20100126133A1 (en) * | 2008-11-26 | 2010-05-27 | Curtis Robert Fekety | Coated Particulate Filter And Method |
US20110104586A1 (en) * | 2008-04-18 | 2011-05-05 | The Regents Of The University Of California | Integrated seal for high-temperature electrochemical device |
US8343686B2 (en) | 2006-07-28 | 2013-01-01 | The Regents Of The University Of California | Joined concentric tubes |
US8445159B2 (en) | 2004-11-30 | 2013-05-21 | The Regents Of The University Of California | Sealed joint structure for electrochemical device |
CN115522145A (zh) * | 2021-09-26 | 2022-12-27 | 哈尔滨工业大学(威海) | 多孔结构的强化工艺及其制品 |
CN117448657A (zh) * | 2023-11-23 | 2024-01-26 | 中国核动力研究设计院 | 一种碳化硼不锈钢复合材料及其制备方法 |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
IT1077238B (it) * | 1977-06-09 | 1985-05-04 | Montedison Spa | Procedimento protettivo per mezzo di vernici inorganiche di superfici metalliche ferrose e non ferrose contro la corrosione da carburazione in alta temperatura eventualmente congiunta a quella di ossidazione |
JPS6362802A (ja) * | 1986-09-03 | 1988-03-19 | Nippon Tungsten Co Ltd | 多孔質金属焼結体 |
JPH0499184A (ja) * | 1990-08-02 | 1992-03-31 | Hino Motors Ltd | セラミックコーティング発泡金属体及びその製造方法 |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE629895A (enrdf_load_stackoverflow) * | 1961-09-29 | 1900-01-01 | ||
FR1464965A (fr) * | 1965-03-15 | 1967-01-06 | Hexcel Products Inc | Procédé de fabrication d'une structure en nid d'abeilles soudée par explosion |
-
0
- BE BE792075D patent/BE792075A/xx not_active IP Right Cessation
-
1971
- 1971-11-30 US US00203364A patent/US3773549A/en not_active Expired - Lifetime
-
1972
- 1972-11-15 CA CA156,746A patent/CA981992A/en not_active Expired
- 1972-11-29 JP JP47119726A patent/JPS4864107A/ja active Pending
- 1972-11-29 GB GB5507372A patent/GB1414519A/en not_active Expired
- 1972-11-29 FR FR7242475A patent/FR2162082B1/fr not_active Expired
Cited By (35)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3922458A (en) * | 1972-11-24 | 1975-11-25 | Curran Oils Ltd | Vitreous enamelling |
US3963502A (en) * | 1973-02-02 | 1976-06-15 | P. R. Mallory & Co., Inc. | Composition for application to die cavity surface |
US4059707A (en) * | 1975-08-29 | 1977-11-22 | Rca Corporation | Method of filling apertures with crystalline material |
US4059712A (en) * | 1976-01-26 | 1977-11-22 | Bothwell Bruce E | Metal-ceramic composite and method for making same |
US4276331A (en) * | 1976-01-26 | 1981-06-30 | Repwell Associates, Inc. | Metal-ceramic composite and method for making same |
US4427721A (en) | 1977-11-01 | 1984-01-24 | United Kingdom Atomic Energy Authority | Method of coating steel substrates to reduce carbonaceous deposition thereon |
US4251272A (en) * | 1978-12-26 | 1981-02-17 | Union Carbide Corporation | Oxidation resistant porous abradable seal member for high temperature service |
US4425411A (en) | 1981-05-21 | 1984-01-10 | Swiss Aluminium Ltd. | Mold with thermally insulating, protective coating |
US4738874A (en) * | 1984-12-28 | 1988-04-19 | Commissariat A L'energie Atomique | Process for the production of porous, permeable mineral membranes |
US4713300A (en) * | 1985-12-13 | 1987-12-15 | Minnesota Mining And Manufacturing Company | Graded refractory cermet article |
US4743511A (en) * | 1985-12-13 | 1988-05-10 | Minnesota Mining And Manufacturing Company | Graded refractory cermet article |
WO1989011342A1 (en) * | 1988-05-24 | 1989-11-30 | Ceramem Corporation | Porous inorganic membrane with reactive inorganic binder, and method of forming same |
US5364586A (en) * | 1993-08-17 | 1994-11-15 | Ultram International L.L.C. | Process for the production of porous membranes |
WO1995005256A1 (en) * | 1993-08-17 | 1995-02-23 | Ultram International, L.L.C. | Process for the production of porous membranes |
US5996497A (en) * | 1998-06-12 | 1999-12-07 | Eastman Kodak Company | Method of making a durable hydrophilic layer |
US6416871B1 (en) | 1999-05-27 | 2002-07-09 | Sandvik Ab | Surface modification of high temperature alloys |
AU775455B2 (en) * | 1999-05-27 | 2004-08-05 | Sandvik Intellectual Property Ab | Surface modification of high temperature alloys |
AU775455C (en) * | 1999-05-27 | 2005-04-21 | Sandvik Intellectual Property Ab | Surface modification of high temperature alloys |
WO2000073530A1 (en) * | 1999-05-27 | 2000-12-07 | Sandvik Ab; (Publ) | Surface modification of high temperature alloys |
KR100706936B1 (ko) * | 1999-05-27 | 2007-04-11 | 산드빅 인터렉츄얼 프로퍼티 에이비 | 고온 합금의 표면 개질 |
US7351488B2 (en) | 1999-07-31 | 2008-04-01 | The Regents Of The University Of California | Structures and fabrication techniques for solid state electrochemical devices |
US8283077B1 (en) | 1999-07-31 | 2012-10-09 | The Regents Of The University Of California | Structures and fabrication techniques for solid state electrochemical devices |
US20060057295A1 (en) * | 1999-07-31 | 2006-03-16 | The Regents Of The University Of California | Structures and fabrication techniques for solid state electrochemical devices |
US7118777B2 (en) | 1999-07-31 | 2006-10-10 | The Regents Of The University Of California | Structures and fabrication techniques for solid state electrochemical devices |
US6998009B2 (en) | 2003-06-10 | 2006-02-14 | Ut-Battelle, Llc | Filter and method of fabricating |
US20040253371A1 (en) * | 2003-06-10 | 2004-12-16 | Janney Mark A. | Filter and method of fabricating |
US8445159B2 (en) | 2004-11-30 | 2013-05-21 | The Regents Of The University Of California | Sealed joint structure for electrochemical device |
US8343686B2 (en) | 2006-07-28 | 2013-01-01 | The Regents Of The University Of California | Joined concentric tubes |
WO2008046785A2 (de) | 2006-10-17 | 2008-04-24 | Robert Bosch Gmbh | Verfahren zur stabilisierung und funktionalisierung von porösen metallischen schichten |
WO2008046785A3 (de) * | 2006-10-17 | 2009-05-07 | Bosch Gmbh Robert | Verfahren zur stabilisierung und funktionalisierung von porösen metallischen schichten |
US20110104586A1 (en) * | 2008-04-18 | 2011-05-05 | The Regents Of The University Of California | Integrated seal for high-temperature electrochemical device |
US8486580B2 (en) | 2008-04-18 | 2013-07-16 | The Regents Of The University Of California | Integrated seal for high-temperature electrochemical device |
US20100126133A1 (en) * | 2008-11-26 | 2010-05-27 | Curtis Robert Fekety | Coated Particulate Filter And Method |
CN115522145A (zh) * | 2021-09-26 | 2022-12-27 | 哈尔滨工业大学(威海) | 多孔结构的强化工艺及其制品 |
CN117448657A (zh) * | 2023-11-23 | 2024-01-26 | 中国核动力研究设计院 | 一种碳化硼不锈钢复合材料及其制备方法 |
Also Published As
Publication number | Publication date |
---|---|
FR2162082B1 (enrdf_load_stackoverflow) | 1975-03-28 |
FR2162082A1 (enrdf_load_stackoverflow) | 1973-07-13 |
CA981992A (en) | 1976-01-20 |
JPS4864107A (enrdf_load_stackoverflow) | 1973-09-05 |
BE792075A (fr) | 1973-05-29 |
GB1414519A (en) | 1975-11-19 |
DE2258282A1 (de) | 1973-06-14 |
DE2258282B2 (de) | 1977-07-07 |
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Owner name: CHROMALLOY GAS TURBINE CORPORATION, A DE. CORP., N Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CHROMALLOY AMERICAN CORPORATION;REEL/FRAME:004862/0635 Effective date: 19880311 Owner name: CHROMALLOY GAS TURBINE CORPORATION, BLAISDELL ROAD Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:CHROMALLOY AMERICAN CORPORATION;REEL/FRAME:004862/0635 Effective date: 19880311 |