Patent US3605752A successfully refreshed from Google Patents.
US5223045A
Expired / Lapsed
US
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Refractory metal composite coated article
Assignee: Barson Corp
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Filing: 1989-03-13
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Granted: 1993-06-29
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Expires: 2009-03-13
Abstract
Abstract The coated article includes a refractory metal substrate having an oxidation resistant intermetallic layer formed in situ thereon; e.g., a fused refractory metal silicide layer, and a ceramic layer applied on and adhering to the intermetallic layer to provide enhanced high temperature properties and improved resistance to premature catastrophic failure in high temperature oxidizing environments where dissimilar materials are present that may destructively react with the intermetallic layer.
Inventors
- 👤 Seymour Priceman
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 15:32
CPC Classifications
F; F01; F01D; F01D5/00; F01D5/12; F01D5/28; F01D5/288; C; C23; C23C; C23C28/00; F02; F02F; F02F7/00; F02F7/0085; F02F7/0087; F05; F05D; F05D2300/00; F05D2300/50; F05D2300/504; Y; Y02; Y02T; Y02T50/00; Y02T50/60
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
99 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, and (c) controlling the surface roughness of the intermetallic layer to at least about 160 micro-inches RMS to promote adherence of the ceramic layer thereon.
Claim 2
Independent Claim
99 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, and (c) controlling the surface roughness of the intermetallic layer to at least about 160 micro-inches RMS to promote adherence of the ceramic layer thereon.
Claim 3
Dependent Claim
23 words
The method of claim 1 wherein the surface roughness is controlled to be in the range of about 160 to about 300 micro-inches.
Claim 4
Dependent Claim
22 words
The method of claim 2 wherein the surface roughness is controlled to be in the range of about 20 to 300 micro-inches.
Claim 5
Dependent Claim
23 words
The method of claim 1 wherein the surface roughness of the intermetallic layer is controlled by roughening the surface of the refractory metal.
Claim 6
Dependent Claim
22 words
The method of claim 1 wherein the surface roughness is controlled by controlling the temperature and/or time for forming the intermetallic layer.
Claim 7
Dependent Claim
19 words
The method of claim 1 wherein the surface roughness is controlled by controlling the thickness of the intermetallic layer.
Claim 8
Dependent Claim
33 words
The method of claim 1 wherein the ceramic layer is applied to a thickness of about 5 mils to about 40 mils to provide a thermal barrier between the intermetallic layer and environment.
Claim 9
Dependent Claim
33 words
The method of claim 1 wherein the ceramic layer is applied to a thickness of about 3 mils to about 6 mils to provide a chemical/metallurgical barrier between the intermetallic layer and environment.
Claim 10
Dependent Claim
30 words
The method of claim 1 wherein the ceramic layer is applied to a thickness of about 3 mils to about 10 mils to impart erosion/wear resistance to the coated surface.
Claim 11
Dependent Claim
33 words
The method of claim 1 wherein the ceramic layer exhibits an emissivity of radiation greater than the intermetallic layer and is applied to a thickness of about 1/2 mils to about 3 mils.
Claim 12
Dependent Claim
35 words
The method of claim 1 wherein the reactive metallic material applied in step (a) includes silicon and the silicon reacts with the refractory metal to form a fused oxidation resistant silicide of the refractory metal.
Claim 13
Independent Claim
119 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, (c) controlling the surface roughness of the intermetallic layer to at least about 160 micro-inches RMS to promote adherence of the ceramic layer thereon, and (d) oxidizing the intermetallic layer to form an oxide scale at the interface between the intermetallic layer and ceramic layer.
Claim 14
Independent Claim
119 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, (c) controlling the surface roughness of the intermetallic layer to at least about 160 micro-inches RMS to promote adherence of the ceramic layer thereon, and (d) oxidizing the intermetallic layer to form an oxide scale at the interface between the intermetallic layer and ceramic layer.
Claim 15
Dependent Claim
27 words
The method of claim 12 wherein oxidizing of the intermetallic layer is conducted after the ceramic layer is applied to form an oxide scale at the interface.
Claim 16
Dependent Claim
35 words
The method of claim 12 wherein the reactive metallic material applied in step (a) includes silicon and the silicon reacts with the refractory metal to form a fused oxidation resistant silicide of the refractory metal.
Claim 17
Independent Claim
111 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, and (c) controlling at least one of the temperature and time of heating in step (a) to form the intermetallic layer with a selected surface roughness that promotes adherence of the ceramic layer on the intermetallic layer.
Claim 18
Independent Claim
111 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, and (c) controlling at least one of the temperature and time of heating in step (a) to form the intermetallic layer with a selected surface roughness that promotes adherence of the ceramic layer on the intermetallic layer.
Claim 19
Dependent Claim
28 words
The method of claim 15 wherein at least one of said temperature and time are controlled to provide a surface roughness of at least about 160 micro-inches RMS.
Claim 20
Dependent Claim
38 words
The method of claim 15 wherein in step (a), the rate of heating said refractory metal and said metallic material is controlled to provide the intermetallic layer with a surface roughness of at least about 160 micro-inches RMS.
Claim 21
Independent Claim
106 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, and (c) controlling the thickness of the intermetallic layer formed in step (a) to provide a selected intermetallic layer surface roughness that promotes adherence of the ceramic layer on the intermetallic layer.
Claim 22
Independent Claim
106 words
A method for coating a surface of a refractory metal to provide high temperature oxidation protection, comprising the steps of: (a) forming an oxidation resistant intermetallic layer on the refractory metal by applying a reactive metallic material to said surface and heating said refractory metal and metallic material to a temperature and for a time to form the intermetallic layer in situ on said surface, (b) applying a ceramic layer to the intermetallic layer, and (c) controlling the thickness of the intermetallic layer formed in step (a) to provide a selected intermetallic layer surface roughness that promotes adherence of the ceramic layer on the intermetallic layer.
Claim 23
Dependent Claim
22 words
The method of claim 18 wherein said thickness is controlled to provide a surface roughness of at least about 160 micro-inches RMS.
Claim 24
Dependent Claim
16 words
The method of claim 18 wherein said thickness is about 5 mils to about 8 mils.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-06-28 | 1996-12-28 | 1997-06-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-06-28 | 2000-12-28 | 2001-06-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-06-28 | 2004-12-28 | 2005-06-29 | $7700.00 | Window Closed / Lapsed |