US 12,129,553 B2
Method for manufacturing an abradable layer
Serge Georges Vladimir Selezneff, Moissy-Cramayel (FR); Philippe Charles Alain Le Biez, Moissy-Cramayel (FR); Arnaud Louis Gabriel Fregeac, Moissy-Cramayel (FR); Florence Ansart, Labege (FR); and Claude Gilbert Jean-Pierre Estournes, Rieumes (FR)
Assigned to SAFRAN AIRCRAFT ENGINES, Paris (FR); CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE, Paris (FR); and UNIVERSITE PAUL SABATIER—TOULOUSE III, Toulouse (FR)
Appl. No. 17/255,232
Filed by SAFRAN AIRCRAFT ENGINES, Paris (FR); CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE, Paris (FR); and UNIVERSITE PAUL SABATIER—TOULOUSE III, Toulouse (FR)
PCT Filed Jun. 20, 2019, PCT No. PCT/FR2019/051510
§ 371(c)(1), (2) Date Dec. 22, 2020,
PCT Pub. No. WO2020/002799, PCT Pub. Date Jan. 2, 2020.
Claims priority of application No. 1855682 (FR), filed on Jun. 25, 2018.
Prior Publication US 2021/0317584 A1, Oct. 14, 2021
Int. Cl. C23C 24/08 (2006.01); C04B 41/00 (2006.01); C04B 41/45 (2006.01); B82Y 40/00 (2011.01); F01D 11/12 (2006.01)
CPC C23C 24/085 (2013.01) [C04B 41/0018 (2013.01); C04B 41/0072 (2013.01); C04B 41/4545 (2013.01); B82Y 40/00 (2013.01); F01D 11/122 (2013.01); F05D 2230/90 (2013.01); F05D 2240/55 (2013.01); F05D 2300/2118 (2013.01)] 13 Claims
 
1. A process for manufacturing a substrate coated with an abradable layer, the substrate being a turbomachine part and the process comprising:
forming the abradable layer on a separate substrate comprising a powder composition comprising at least micrometric ceramic particles having a number-average form factor greater than or equal to 3, a mass content of said micrometric ceramic particles in the powder composition being greater than or equal to 85%, the form factor of a particle being defined as the ratio [largest dimension of the particle]/[largest cross-sectional dimension of the particle], by heating said micrometric ceramic particles, as well as any nanometric ceramic particles that may be present, to a first temperature T1 greater than or equal to 600° C. and while the assembly is brought to the first temperature T1, increasing a compression pressure until it reaches, at a first time t1, a plateau at a value Pc which corresponds to the compression pressure to be applied during the sintering of the powder composition; then
increasing the temperature of the powder composition and the separate substrate to the sintering temperature Tf reached at a second time t2; then
maintaining the sintering temperature Tf and the compression pressure Pc until the third time t3 to obtain the abradable layer; and
separating the abradable layer from the separate substrate;
depositing the abradable layer thus formed on a surface of the substrate, and
bonding the abradable layer thus deposited on the surface of the substrate wherein a temperature imposed during sintering, a sintering time and a compression pressure applied are selected so as to obtain a volume porosity rate of the abradable layer greater than or equal to 20%.