Refractory composite material and method of making such material

Stock material or miscellaneous articles – Coated or structually defined flake – particle – cell – strand,... – Rod – strand – filament or fiber

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4272481, 427249, 427250, 428378, 428379, 428381, 428408, B32B 900

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active

048637980

ABSTRACT:
A porous substrate is formed from discrete elements preferably anisotropic and permeable to oxygen and preferably having a first coefficient of thermal expansion. A pyrolytic material permeable to oxygen may be deposited in a thin layer on the discrete elements. A barrier material (e.g. boron carbide or silicon carbide) may be deposited in a thin layer on the pyrolytic material to inhibit diffusion of elements into the pyrolytic material. A material impermeable to oxygen (e.g. boron nitride or silicon nitride) may be deposited in a thin layer on the barrier material. A refractory matrix permeable to oxygen may be deposited on the impermeable material. The matrix may include a metallic element (e.g. silicon, hafnium, tantalum or zirconium) and another element (e.g. oxygen, nitrogen, carbon or boron) chemically bonded to the metallic element. The matrix may have a second coefficient of thermal expansion different from the first coefficient and may have a minimal bond to the substrate. The matrix is accordingly able to move relative to the substrate with changes in temperature, partly because the pyrolytic material contributes to a shear between the matrix and substrate. A refractory material impermeable to oxygen may be deposited in a thin layer on the matrix and may include a metallic element (e.g. silicon, hafnium, tantalum or zirconium) and an element (e.g. oxygen, nitrogen and boron) chemically bonded to the metallic element. The different layers may be deposited on the substrate, each in a substantially uniform thickness, at an elevated temperature and at pressures pulsating at a particular rate, and in reverse directions, between first and second particular limits.

REFERENCES:
patent: 4596741 (1986-06-01), Endou et al.
patent: 4663230 (1987-05-01), Tennent
patent: 4772513 (1988-09-01), Sakamoto et al.

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