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US-12617734-B2 - Ceramic matrix composite article and method of making the same

US12617734B2US 12617734 B2US12617734 B2US 12617734B2US-12617734-B2

Abstract

A method of forming a feature on an article includes applying a powder material stock to a surface of an article, the powder material stock being capable of being transformed into a solid feature by the application of energy; applying energy to a portion of the powder material stock within a footprint of a feature to form the feature within the footprint; and removing excess powder material stock from the surface of the article. A coated article is also disclosed.

Inventors

  • Michael G. McCaffrey

Assignees

  • RTX CORPORATION

Dates

Publication Date
20260505
Application Date
20230807

Claims (14)

  1. 1 . A method of forming a feature on an article, comprising: (a) applying a powder material stock to a surface of an article, the powder material stock being capable of being transformed into a solid feature by application of energy; (b) applying energy to a portion of the powder material stock within a footprint of a feature to form the feature within the footprint; (c) removing excess powder material stock from the surface of the article; (d) applying a second powder material stock to the surface of the article, the second powder material stock being capable of being transformed into a solid coating by application of energy; (e) applying energy to a portion of the second powder material stock within a coating layer footprint to form a coating layer over the feature, wherein the coating layer overhangs an outwardly facing surface of the feature and forms a pocket underneath the coating layer and adjacent the feature; (f) removing excess of the second powder material stock from the surface of the article and the feature; and (g) applying an environmental barrier coating over the article including over the feature, the pocket interlocking with the environmental barrier coating to mechanically tack the environmental barrier coating on the article.
  2. 2 . The method of claim 1 , where a footprint of the powder material stock is larger than the footprint of the feature.
  3. 3 . The method of claim 1 , wherein powder material stock outside of the footprint of the feature is undisturbed after the step of applying energy.
  4. 4 . The method of claim 1 , further comprising a step of grinding the feature after the removing step.
  5. 5 . The method of claim 1 , wherein the article is gas turbine engine article made of a ceramic material composite article.
  6. 6 . The method of claim 1 , wherein the coating layer footprint is larger than the footprint of the feature such that the coating layer surrounds all exposed surface of the feature.
  7. 7 . The method of claim 1 , wherein the step of applying the powder material stock includes disposing the powder material stock in a slurry and applying the slurry to the surface of the article.
  8. 8 . The method of claim 7 , wherein the slurry includes a binder that temporarily adheres the powder material stock to the surface of the article.
  9. 9 . The method of claim 7 , further comprising drying the slurry prior to the step of applying energy.
  10. 10 . The method of claim 1 , wherein the energy is in the form of at least one of a laser beam or microwave energy.
  11. 11 . The method of claim 1 , wherein the article is a ceramic matrix composite article.
  12. 12 . The method of claim 1 , wherein the powder material stock and the second powder material stock are of different composition from each other.
  13. 13 . The method of claim 1 , further comprising repeating steps (a), (b), and (c) to provide an array of features on the article.
  14. 14 . The method of claim 13 , wherein the array is a grid.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of Provisional U.S. Patent Application Ser. No. 63/395,537 filed Aug. 5, 2022; the disclosure of which is incorporated by reference in its entirety herein. BACKGROUND A gas turbine engine typically includes a fan section, a compressor section, a combustor section and a turbine section. Air entering the compressor section is compressed and delivered into the combustion section where it is mixed with fuel and ignited to generate a high-energy exhaust gas flow. The high-energy exhaust gas flow expands through the turbine section to drive the compressor and the fan section. The compressor section typically includes low and high pressure compressors, and the turbine section includes low and high pressure turbines. This disclosure relates to composite articles, such as those used in gas turbine engines, and methods of coating such articles. Components, such as gas turbine engine components, may be subjected to high temperatures, corrosive and oxidative conditions, and elevated stress levels. Ceramic materials such as ceramic matrix composites may be suitable for use in such conditions. SUMMARY A method of forming a feature on an article according to an exemplary embodiment of this disclosure, among other possible things includes applying a powder material stock to a surface of an article, the powder material stock being capable of being transformed into a solid feature by the application of energy; applying energy to a portion of the powder material stock within a footprint of a feature to form the feature within the footprint; and removing excess powder material stock from the surface of the article. In a further example of the foregoing, a footprint of the powder material stock is larger than the footprint of the feature. In a further example of any of the foregoing, powder material stock outside of the footprint of the feature is undisturbed after the step of applying energy. In a further example of any of the foregoing, the method also includes the step of grinding the feature after the removing step. In a further example of any of the foregoing, the article is a ceramic material composite article. In a further example of any of the foregoing, the method also includes applying a second powder material stock to the surface of the article, the second powder material stock being capable of being transformed into a solid coating by the application of energy; applying energy to a portion of the second powder material stock within a coating layer footprint to form a coating layer over the feature; and removing excess of the second powder material stock from the surface of the article and the feature. In a further example of any of the foregoing, the coating layer footprint is larger than the footprint of the feature such that the coating layer surrounds all exposed surface of the feature. In a further example of any of the foregoing, the coating layer is disposed on an outwardly facing surface of the feature and overhangs the outwardly facing surface of the feature, forming a pocket underneath the layer and adjacent the feature. In a further example of any of the foregoing, the step of applying the powder material stock includes disposing the powder material stock in a slurry and applying the slurry to the surface of the article. In a further example of any of the foregoing, the slurry includes a binder that temporarily adheres the powder material stock to the surface of the article. In a further example of any of the foregoing, the method also includes drying the slurry prior to the step of applying energy. In a further example of any of the foregoing, the energy is in the form of a laser beam. In a further example of any of the foregoing, the energy is in the form of microwave energy. In a further example of any of the foregoing, the article is a ceramic matrix composite article. A coated article according to an exemplary embodiment of this disclosure, among other possible things includes an article, a coating disposed on the article, and one or more tacks disposed on the article. The one or more tacks each include a feature, and at least one layer disposed on an outwardly facing surface of the feature and overhanging the outwardly facing surface such that a pocket is disposed under the layer adjacent the feature. The pocket mechanically tacks the coating to the article. In a further example of the foregoing, the coating is an environmental barrier coating. In a further example of any of the foregoing, the at least one layer includes two layers. The two layers form a taper with respect to the feature. In a further example of any of the foregoing, the one or more features are ribs. In a further example of any of the foregoing, the one or more features comprise an array of features. In a further example of any of the foregoing, the article is a ceramic matrix composite article. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of