US 11,667,580 B2
Method for producing a surface layer on a ceramic matrix composite
Pathikumar Sellappan, Seal Beach, CA (US); Sungbo Shim, Irvine, CA (US); and Kevin Mark Lukhard, Anaheim, CA (US)
Assigned to ROLLS-ROYCE HIGH TEMPERATURE COMPOSITES INC., Cypress, CA (US)
Filed by Rolls-Royce High Temperature Composites Inc., Cypress, CA (US)
Filed on Sep. 4, 2020, as Appl. No. 17/12,977.
Claims priority of provisional application 62/896,840, filed on Sep. 6, 2019.
Prior Publication US 2021/0070664 A1, Mar. 11, 2021
Int. Cl. C04B 35/80 (2006.01); F01D 25/08 (2006.01); C04B 35/628 (2006.01); C04B 35/657 (2006.01); C04B 41/00 (2006.01); C04B 41/50 (2006.01); C04B 41/87 (2006.01); B28B 11/04 (2006.01)
CPC C04B 35/80 (2013.01) [B28B 11/041 (2013.01); C04B 35/62863 (2013.01); C04B 35/62873 (2013.01); C04B 35/657 (2013.01); C04B 41/009 (2013.01); C04B 41/5059 (2013.01); C04B 41/87 (2013.01); F01D 25/08 (2013.01); C04B 2235/3826 (2013.01); C04B 2235/48 (2013.01); C04B 2235/5252 (2013.01); C04B 2235/616 (2013.01); F05D 2220/32 (2013.01); F05D 2230/20 (2013.01); F05D 2230/90 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method comprising:
applying a resin coating comprising a carbonaceous resin and a particulate to a surface of a preform;
controlling a viscosity of the carbonaceous resin, such that the resin coating does not infiltrate the preform;
adding the preform to a tooling;
curing the preform positioned in the tooling;
removing the tooling;
pyrolyzing the resin coating on the surface of the preform to yield a resin carbon-char layer on the surface of the preform; and
infiltrating the preform and the resin carbon-char layer with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide, wherein during the infiltration the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform.