Deformation process for producing stress relieved metal/ceramic abradable seals

Claim 2

Process for bonding a multi-layer metal/ceramic abradable composite to a deformable metallic substrate which comprises placing said abradable composite, in the unsintered state, with its metal-rich surface in contact with said substrate, heating said composite and substrate under pressure to a sintering temperature sufficient to sinter said composite and bond to said substrate, maintaining such a temperature until said sintering and bonding are complete, substantially removing said pressure, then cooling the thus formed structure to ambient temperature and then fastening reinforcing members to the backside of said substrate to rigidify it.

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 1 wherein said pressure is at least 5 pounds per square inch during heating.

Claim 8

Process according to claim 1 wherein said reinforcing members are metal bars.

Claim 9

Process according to claim 7 wherein said metal bars are welded to said substrate backside.

Claim 10

Process for producing a porous abradable seal 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) pressing the composite in a suitable fixture under pressure and then slowly drying the composite to thereby form a multi-layer composite, (c) placing the dried composite on a deformable metallic substrate with said metallic bottom layer of said composite in contact with said substrate, (d) heating said composite in contact with said substrate under pressure to a sintering temperature sufficient to sinter said composite and bond said composite to said substrate and maintaining such a temperature until said sintering and bonding are complete, (e) substantially removing said pressure on the structure formed in step d, and then cooling said structure to ambient temperature whereby said metallic substrate assumes the desired final configuration, and (f) fastening reinforcing members to the backside of said substrate to rigidify it.

Claim 11

Process for producing a porous abradable seal 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) pressing the composite in a suitable fixture under pressure and then slowly drying the composite to thereby form a multi-layer composite, (c) placing the dried composite on a deformable metallic substrate with said metallic bottom layer of said composite in contact with said substrate, (d) heating said composite in contact with said substrate under pressure to a sintering temperature sufficient to sinter said composite and bond said composite to said substrate and maintaining such a temperature until said sintering and bonding are complete, (e) substantially removing said pressure on the structure formed in step d, and then cooling said structure to ambient temperature whereby said metallic substrate assumes the desired final configuration, and (f) fastening reinforcing members to the backside of said substrate to rigidify it.

Claim 12

Process according to claim 9 wherein step c the metallic substrate is first coated with a brazing powder prior to the placing of the composite on it.

Claim 13

Process according to claim 9 wherein steps d and e are conducted in an inert atmosphere.

Claim 14

Process according to claim 11 wherein said inert atmosphere is a vacuum of at least 10 -4 torr.

Claim 15

Process according to claim 11 wherein said inert atmosphere is selected from the group consisting of argon, hydrogen and nitrogen.

Claim 16

Process according to claim 9 wherein said pressure is at least 5 pounds per square inch during step d.

Claim 17

Process according to claim 9 wherein said reinforcing members are metal bars.

Claim 18

Process according to claim 15 wherein said metal bars are welded to said substrate backside.