Patent Description:
An attempt at intermetallic compositing via hot pressing in <NPL>. In an exemplary process, an intermetallic is cast and powdered such as via mechanical attrition or atomization. The powder is then mixed with reinforcement fibers or into a fiber preform. The mixture is then hot pressed to fully consolidate into a composite.

Due to deficiencies in the hot pressing, an in situ formation technique has been proposed. This technique omits the fiber reinforcement. In such an in situ technique, a long rod of the intermetallic is prepared by direct casting or by powder metallurgical consolidation. The rod is reprocessed by zone melting to traverse the melt region along the rod length to cause directional solidification. The term "composite" is used due to the presence of multiple phases in a coarse microstructure causing behavior characteristic of composites.

Such an in situ technique is disclosed in<NPL>and. An intermetallic of Nb-27Mo-27Cr-9Al-9Si (in at. %) is one identified material.

Separately, an intermetallic of that Nb-27Mo-27Cr-9Al-9Si (in at. %) is discussed in<NPL>.

Additionally, ceramic matrix composites (CMC) have been formed such as by infiltrating liquid Si (melting point <NUM>°F) into an SiC fiber preform. <CIT> discloses the manufacture of a composite by infiltrating a ceramic preform.

One aspect of the disclosure involves an intermetallic matrix composite comprising: an intermetallic matrix; and a ceramic reinforcement. The intermetallic matrix comprises, in atomic percent: <NUM> ±<NUM> Nb; <NUM> ±<NUM> Mo; <NUM> ±<NUM> Cr; <NUM> ±<NUM> Si; <NUM> ±<NUM> Al; and no more than <NUM> other alloying elements and impurities, if any. The other alloying elements and impurities comprise Sn, Re, refractory elements, and/or transition metals. The intermetallic matrix comprises a eutectic having at least two phases, wherein two phases combine to form at least <NUM>% by volume of the matrix and each is at least <NUM>% by volume of the matrix, and the two phases comprise: a first phase being of the type Cr<NUM>Nb with C14/C15 crystal structure; and a second phase being of the type Cr<NUM>Si with A15 crystal structure.

An optional embodiment includes the intermetallic matrix comprising a third phase forming <NUM> % to <NUM> % by volume of the matrix and comprising: a majority by weight and volume Nb-Cr-Mo solid solution with A2 structure.

An optional embodiment includes the intermetallic matrix comprising, in atomic percent: <NUM> ±<NUM> Nb; <NUM> ±<NUM> Mo; <NUM> ±<NUM> Cr; <NUM> ±<NUM> Si; and <NUM> ±<NUM> Al.

An optional embodiment includes the intermetallic matrix comprising for said other alloying elements, in atomic percent: <NUM> to <NUM> Sn.

An optional embodiment includes the intermetallic matrix comprising for said other alloying elements, in atomic percent: <NUM> to <NUM> Re.

An optional embodiment includes the intermetallic matrix comprising for said other alloying elements, in atomic percent: <NUM> to <NUM> Sn and <NUM> to <NUM> Re.

An optional embodiment includes the intermetallic matrix comprising, in atomic percent: no more than <NUM> total all other refractory elements and no more than <NUM> individual all other transition metals.

An optional embodiment includes the intermetallic matrix being: Nb-27Mo-27Cr-9Al-9Si (in at.

An optional embodiment include the intermetallic matrix having a melting point of: <NUM>°F to <NUM>°F.

An optional embodiment includes the ceramic reinforcement comprising alumina.

An optional embodiment of any of the foregoing embodiments may additionally and/or alternatively include the ceramic reinforcement comprising coated SiC fiber.

An optional embodiment includes the coating on the SiC fiber comprising at least one of mullite and alumina.

An optional embodiment include the ceramic reinforcement comprising a woven preform.

An optional embodiment includes the ceramic reinforcement comprising fibers coated with A15(Cr<NUM>Si) phase-forming metallic elements replacing Si sites.

An optional embodiment includes a turbine engine component comprising a body of the intermetallic matrix composite.

An optional embodiment includes a silicide coating on the body.

An optional embodiment includes a metallic inner member where the body comprises a shell surrounding the metallic inner member.

Another aspect includes a method for manufacturing the intermetallic matrix composite. The method comprises: providing a preform of the ceramic reinforcement; infiltrating the preform with molten alloy at a temperature of <NUM>°F to <NUM>°F; and allowing the alloy to solidify to from the intermetallic matrix.

An optional embodiment includes the infiltration being a vacuum infiltration or a pressure-assisted infiltration.

Infiltration preparation of a fiber-reinforced high temperature metallic matrix composite or intermetallic matrix composite raises competing considerations. There are competing considerations of matrix pour temperature and fluidity. For sufficient fluidity to achieve infiltration, the pour temperature may be high enough to damage or destroy the fibers.

Use of a eutectic intermetallic matrix composite may provide sufficiently low pour temperature with sufficiently high fluidity to achieve a useful result. In particular, Nb-27Mo-27Cr-9Al-9Si (in at. %) has a melting point of about <NUM>°F (<NUM>) with high fluidity. Other intermetallics may have too high a melting point (MoSi<NUM> - <NUM>°F (<NUM>)). Yet others may have insufficient fluidity (e.g., Cr<NUM>Nb, a single phase intermetallic having a comparable melting point of <NUM>°F (<NUM>), but unlikely to have sufficient fluidity). Also, the multi-element Nb-27Mo-27Cr-9Al-9Si is likely to give higher creep resistance and a better opportunity to achieve balance of engineering properties than a two-component, single phase, material.

To help withstand infiltration temperatures in the vicinity of <NUM>°F (<NUM>) or higher, the fibers may be of a high melt or disassociation temperature material or may be coated with such a material. Examples are alumina fibers and alumina-coated SiC fibers. In an example, SiC fibers are coated with alumina via chemical vapor deposition (CVD) prior to weaving or otherwise lacing in a preform mold. Alternative coatings are mullite or mullite-alumina mixtures or layered variations.

In an exemplary process, the monolithic or coated fibers are woven into a preform and placed in a mold (optionally with sacrificial or non-sacrificial cores such as molded alumina or zirconia). An exemplary mold is a sacrificial refractory container (e.g., formed of a refractory metal (e.g., in foil form) such as niobium or molybdenum). Such foil (e.g., folded or pressed to shape) may be a stand-alone mold or may be a liner for a ceramic mold or water-cooled copper mold.

Exemplary components to be molded are turbine engine vanes, blades, blade outer air seals (BOAS) and sub-components thereof. For example, the component could be a blade with airfoil, attachment root, and platform in between. It could be a vane with airfoil, inner diameter (ID) shroud and outer diameter (OD) shroud. Or the component could be an airfoil shell (e.g., replacing a CMC airfoil shell) in a vane wherein the vane has a metallic spar extending spanwise through the shell between ID and OD shrouds.

A master heat of the alloy is prepared via induction or electron beam zone melting techniques. The master heat is then remelted in a crucible to a sufficient heat for needed fluidity. Conventional casting practice is to provide at least <NUM>°F (<NUM>) superheat over the melting point. But because the liquid metal is expected to fill in tight passages within the fiber pre-form and because the alloy is a eutectic composition, upward adjustment in the superheat may be required to provide sufficient fluidity achieve complete infiltration/filling.

The remelt is then poured into the mold, infiltrating the preform. Exemplary infiltration is infiltration is a vacuum infiltration or a pressure-assisted infiltration. The poured material is then cooled (e.g., via withdrawal from the furnace or rapidly if poured in a water cooled copper cavity) to solidify. Mold removal or de-shelling may be performed by mechanical and/or chemical methods (this may include peeling and/or grinding off the foil). Core removal (de-coring) of any sacrificial cores may be via leaching (alkaline and/or acidic) and/or thermo-oxidative process. The relative large cross-sectional thickness of the cores allows them to be leached and/or oxidized out without similar destruction of the fiber reinforcement. Non-sacrificial cores may form liners of passageways or compartments.

By way of schematic example, <FIG> shows a turbine engine component having a body formed by composite <NUM> comprising a matrix <NUM> and a reinforcement <NUM>. The exemplary reinforcement is formed as a preform of one or more tows of ceramic fibers <NUM>. Exemplary fiber transverse dimension (e.g., diameter is <NUM> to <NUM>, more particularly <NUM> to <NUM> or <NUM> to <NUM>.

The matrix <NUM> is essentially a two-phase matrix (e.g., with the two phases <NUM>, <NUM> (<FIG>) accounting for <NUM>% or more of the matrix volume and each accounting for at least <NUM>% of the matrix volume). The first phase <NUM> is characterized by being of the type Cr<NUM>Nb Laue phase with C14/C15 hexagonal or cubic crystal structure, respectively. The type Cr<NUM>Nb allows some substitutes for either element. For example, Cr may be replaced by Mo, and Nb may be replaced by Ta.

The second phase <NUM> is characterized by being of the type Cr<NUM>Si with A15 cubic crystal structure. Similarly, the type Cr<NUM>Si allows some substitutes for either element. For example, Cr may be replaced by Mo or Nb and Si may be replaced by Al, Sn, Bi, Sb, Li, and Ga.

Exemplary size of the phases <NUM> and <NUM> is <NUM> to <NUM>, more particularly <NUM> to <NUM>.

As noted above, a nominal matrix example is 27Mo-27Cr-9Al-9Si (in at. More broadly such a material may have (in at. %): <NUM> ±<NUM> Nb; <NUM> ±<NUM> Mo; <NUM> ±<NUM> Cr; <NUM> ±<NUM> Si; <NUM> ±<NUM> Al; and no more than <NUM> other alloying elements and impurities, if any. Narrower limits on the elemental ranges are ±<NUM> and narrower alloying element limit is <NUM> and a narrower impurity limit is <NUM> with an alternate combined alloying elements and impurity limit being <NUM> or <NUM> or <NUM> or <NUM>. Exemplary limits on individual alloying elements are <NUM> or <NUM>. Exemplary limits on individual impurities are <NUM> or <NUM> or <NUM>.

Among additional alloying elements are Sn and Re. Sn in small amounts (e.g., <NUM> to <NUM> atomic %) may improve toughness. Re, in small amounts (e.g., <NUM> to <NUM> atomic %) may improve creep resistance. The upper limits are constrained by their effect on reducing fluidity. Ta may have a similar effect to Re. Due to the fluidity effect, an exemplary limit on refractory elements as alloying elements and impurities is <NUM>% total and <NUM>% individually, more narrowly <NUM>% total and <NUM>% for refractories other than said Re.

Among likely minor alloying elements and impurities may be transition metals such as Ni, Co, and Fe. These may also reduce fluidity. An exemplary atomic % limit on transition metals as alloying elements and impurities is <NUM>% total and <NUM>% individually or, more narrowly, <NUM>% and <NUM>%, respectively.

A further matrix variation is a three-phase system (<FIG>) wherein a third phase <NUM> is present in a significant volume fraction (e.g., <NUM>% to <NUM>% or <NUM>% to <NUM>%). The exemplary third phase may comprise a majority by weight and volume Nb-Cr-Mo solid solution with A2 structure. <FIG> shows this phase dispersed in a field <NUM> of the phases <NUM> and <NUM> (<FIG>). The formation of the third phase will depend on cooling parameters, chiefly rate. The third phase may serve to improve ductility but will reduce oxidation resistance. Thus, its formation may be undesirable in most applications. In such a three-phase system, by volume the first phase <NUM> may account for an exemplary <NUM>% to <NUM>% (e.g., about <NUM>%), the second phase <NUM> for an exemplary <NUM>% to <NUM>% (e.g., about <NUM>%), and miscellaneous phases, if any up to <NUM>%, or up to <NUM>%. However, even if the third phase <NUM> forms, a subsequent heat treatment may decompose it back to the phases <NUM> and <NUM>.

If the fibers are coated, exemplary coating thickness is <NUM> to <NUM> or <NUM> to <NUM>. <FIG> shows a fiber having a substrate <NUM> (e.g., the SiC noted above) and a coating <NUM> (e.g., the alumina noted above).

In various implementations, the presence of the reinforcement may improve the strength and/or toughness of the composite relative to the two phase (or three-phase) intermetallic eutectic alone. For this purpose as is conventionally done with ceramic matrix composite (CMC), the fibers may be coated (instead of or over the alumina coating) such that a weak interface bonding is achieved. The weak interface bonding lets the matrix slide with respect to the fiber and any crack formed in the matrix is arrested at the interface. This mechanism improves the fracture toughness of the material. However, this may be balanced with the environmental resistance of the coating (particularly in composites where the fibers extend to the surface and are exposed to the in-use environment), otherwise the extremely weak interface may not allow sufficient load transfer from matrix to the fibers.

In contrast to CMC, the matrix <NUM> is intermetallic with largely metallic characteristics. If the fibers are ceramic or ceramic-coated, the intermetallic-to-ceramic interface is expected to be weak. But because many other low melting elements such as Ga, Ge, As, Cd, In, Sn, Sb, and Bi can substitute for either Si or Al in forming a high melting intermetallic of the A15 structural form (type) Cr<NUM>Si or Nb<NUM>Al, such elements can be used for coating the fibers (e.g., the alumina fibers or SiC fibers or alumina-coated SiC fibers). Especially among these elements, Sn is of great interest because experiments seem to indicate that replacing Al with Sn in the base alloy improves the toughness of the base alloy. Sn is also environmentally advantageous and economical because the coating process may be extremely simple either through liquid immersion or surface-tension driven process (e.g., capillary action or wicking) or vapor deposition.

In the same vein, other metallic elements such as Ni, Co, Ti, Ag, Au, and Pt may also be used in fiber coating to create a weak and environmentally protective interface for the fibers. Considerations of these metallic elements in CMC is generally not made due to their metallic nature. But with the intermetallic matrix, any metallic elements at low concentration can be tolerated without lowering the melting point of the interface.

In a further variation, the entire composite body may bear a coating (e.g., for oxidation resistance, thermal protection, abrasion/mechanical protection and the like). One example of a coating <NUM> (<FIG>), which may be a base layer for further coating (not shown), is a silicide. An exemplary silicide is R512E/R522 by Hitemco, Inc. , Old Bethpage, New York and may be applied by a slurry process. Similarly some newly developed coatings are two layer coatings, where a first layer of NbSi<NUM> is applied by halide activated packed cementation (HAPC) and a second layer of MoSi<NUM> is applied by supersonic atmospheric plasma spray (SAPS) and may also be applicable.

Claim 1:
An intermetallic matrix composite (<NUM>) comprising:
an intermetallic matrix (<NUM>); and
a ceramic reinforcement (<NUM>),
wherein the intermetallic matrix (<NUM>) comprises, in atomic percent:
<NUM> ±<NUM> Nb;
<NUM> ±<NUM> Mo;
<NUM> ±<NUM> Cr;
<NUM> ±<NUM> Si;
<NUM> ±<NUM> Al; and
no more than <NUM> other alloying elements and impurities, if any, wherein the other alloying elements and impurities comprise Sn, Re, refractory elements, and/or transition metals; and
wherein the intermetallic matrix comprises a eutectic having at least two phases, wherein two phases (<NUM>, <NUM>) combine to form at least <NUM>% by volume of the matrix (<NUM>) and each is at least <NUM>% by volume of the matrix (<NUM>), and the two phases comprise:
a first phase (<NUM>) being of the type Cr<NUM>Nb with C14/C15 crystal structure; and
a second phase (<NUM>) being of the type Cr<NUM>Si with A15 crystal structure.