Stress relieving of metal/ceramic abradable seals

Claim 2

Process for bonding a multi-layer ceramic/metal abradable composite having a ceramic-rich surface, a metal-rich surface and at least one intermediate layer to a metallic substrate which comprises placing said abradable composite with its metal-rich surface in contact with said substrate, heating said composite and substrate to a sintering temperature sufficient to bond said composite to said substrate, thereafter cooling the thus formed structure in such a manner that before the onset of elastic stresses in said structures due to said cooling a temperature differential is established across the structure, with a temperature of said substrate being maintained consistently lower than the temperature of the ceramic-rich surface of said composite during the remainder of the cooling to ambient temperatures.

Claim 3

Process according to claim 1 wherein the surface of said substrate is coated with a brazing powder prior to heating.

Claim 4

Process according to claim 1 wherein said heating to said sintering temperature and cooling are conducted in an inert atmosphere.

Claim 5

Process according to claim 3 wherein said inert atmosphere is a vacuum of at least 10 -4 torr.

Claim 6

Process according to claim 3 wherein said inert atmosphere is selected from the group consisting of argon, hydrogen and nitrogen.

Claim 7

Process according to claim 3 wherein said inert atmosphere is a vacuum during heating of said composite and substrate and is argon gas during the cooling of said structure.

Claim 8

Process according to claim 1 wherein said composite and said substrate are pressed together during said heating and cooling.

Claim 9

Process according to claim 7 wherein said pressure is at least 5 pounds per square inch during heating and at least 5 pounds per square inch during cooling.

Claim 10

Method according to claim 1 wherein said sintering temperature is in excess of 800° C. and said temperature differential is at least 200° C. when the substrate has cooled to 860° C.

Claim 11

Process for producing a porous abradable seal for use on a turbine engine surface which comprises: a. forming a composite comprising a top layer of substantially all ceramic material, at least one intermediate layer of a mixture of ceramic material and a metallic bottom layer b. retaining the assembled layers in a suitable fixture under pressure and then slowly heating to dryness to thereby form a multi-layer composite c. placing the dried composite on a metallic substrate with said metallic bottom layer of said composite in contact with said substrate d. heating said composite in contact with said substrate to a sintering temperature sufficient to bond said composite to said substrate e. cooling the structure formed in step d. to an ambient temperature in such a manner that before said cooling progresses to a temperature at which stresses are set up in structures by said cooling, a temperature differential is established across said structure, with the temperature of said substrate being maintained consistently lower than the temperature of said top layer of said composite during the remainder of said cooling.

Claim 12

Process for producing a porous abradable seal for use on a turbine engine surface which comprises: a. forming a composite comprising a top layer of substantially all ceramic material, at least one intermediate layer of a mixture of ceramic material and a metallic bottom layer b. retaining the assembled layers in a suitable fixture under pressure and then slowly heating to dryness to thereby form a multi-layer composite c. placing the dried composite on a metallic substrate with said metallic bottom layer of said composite in contact with said substrate d. heating said composite in contact with said substrate to a sintering temperature sufficient to bond said composite to said substrate e. cooling the structure formed in step d. to an ambient temperature in such a manner that before said cooling progresses to a temperature at which stresses are set up in structures by said cooling, a temperature differential is established across said structure, with the temperature of said substrate being maintained consistently lower than the temperature of said top layer of said composite during the remainder of said cooling.

Claim 13

Process according to claim 10 wherein in step c the metallic substrate is first coated with a brazing powder prior to the placing of the composite on it.

Claim 14

Process according to claim 10 wherein steps d and e are conducted in an inert atmosphere.

Claim 15

Process according to claim 12 wherein said inert atmosphere is a vacuum of at least 10 -4 torr.

Claim 16

Process according to claim 12 wherein said inert atmosphere is selected from the group consisting of argon, hydrogen and nitrogen.

Claim 17

Process according to claim 12 wherein said inert atmosphere is a vacuum in step d and argon gas in step c.

Claim 18

Process according to claim 10 wherein said composite and said substrate are pressed together during steps d and e.

Claim 19

Process according to claim 10 wherein said pressure is at least 5 pounds per square inch during step d and at least 5 pounds per square inch during step e.

Claim 20

Method according to claim 10 wherein said temperature differential in step e is at least 200° C.