A multilayer article comprises a substrate comprising a ceramic or a silicon-containing metal alloy. The ceramic is a Si-containing ceramic or an oxide ceramic with or without silicon. An outer layer overlies the substrate and at least one intermediate layer is located between the outer layer and the substrate. An optional bond layer is disposed between the at least one intermediate layer and the substrate. The at least one intermediate layer may comprise an optional chemical barrier layer adjacent the outer layer, a mullite-containing layer and an optional chemical barrier layer adjacent to the bond layer or substrate. The outer layer comprises a compound having a low coefficient of thermal expansion selected from one of the following systems: rare earth (RE) silicates; at least one of hafnia and hafnia-containing composite oxides; zirconia-containing composite oxides and combinations thereof.
An environmental barrier coating material comprising one or more constituents selected from a group consisting of hafnia; hafnia stabilized by one or more rare-earth oxides and/or silica; zirconia-containing hafnia; and zirconia-containing hafnia stabilized by one or more rare-earth oxides and/or silica, which when formed as a coating structure for covering a substrate which has a low thermal expansion coefficient, has hafnon (HfSiO.sub.4) serving as a first layer directly formed on the substrate, and hafnia with which the first layer is coated as a second layer.
A coating system for Si-containing materials, particularly Si-based composites used to produce articles exposed to high temperatures. The coating system is a compositionally-graded thermal/environmental barrier coating (T/EBC) system that includes an intermediate layer containing yttria-stabilized hafnia (YSHf) and mullite, alumina and/or an aluminosilicate, which is used in combination with an inner layer between a Si-containing substrate and the intermediate layer and a thermal-insulating top coat overlying the intermediate layer. The intermediate layer provides environmental protection to the silicon-containing substrate, and has a coefficient of thermal expansion between that of the top coat and that of the inner layer so as to serve as a transition layer therebetween. The intermediate layer is particular well suited for use in combination with an inner layer of an alkaline earth metal aluminosilicate (such as BSAS) and a top coat formed of YSZ or YSHf.
A bond coat system for silicon based substrates wherein a compliant layer having an elastic modulus of between 30 and 130 GPa is provided between the silicon based substrate and a silicon metal containing oxygen gettering layer.
An environmental barrier coating for a component including silicon that has a first coefficient of thermal expansion is provided. The environmental coating includes a silicon bondcoat that is bonded to at least a portion of an outer surface of the component. An intermediate layer is bonded to the silicon bondcoat and has a second coefficient of thermal expansion matched to the first coefficient of thermal expansion. The intermediate layer has a general composition of RE.sub.2Si.sub.2O.sub.7. A protective layer is bonded to the intermediate layer and has a general composition of RE.sub.2SiO.sub.5. A surface layer is bonded to the protective layer. The surface layer includes RE and has a ratio of RE to oxygen of at least 2:3.
A shell mold for casting molten material to form an article is described. The mold includes a shell for containing the molten material, formed from at least one of yttrium silicates, zirconium silicates, hafnium silicates, and rare earth silicates. The mold also includes a facecoat disposed on an inner surface of the shell that contacts the molten material. The facecoat can be made from the materials described above. A method of casting a niobium-silicide article is also described, using the shell mold described herein. A method of making the ceramic shell mold is described as well, along with a slurry composition used in the manufacture of the shell mold.
