Boron-Silicon Oxidation Coating for Wide-Range C-C Composites
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Solution Overview
Problem
Current oxidation protection systems for carbon-carbon composite structures are limited by their temperature range and susceptibility to degradation, failing to effectively protect against oxidation across a broad temperature spectrum, leading to material loss and reduced service life.
Innovation Solution
A method involving a boron-glass and silicon-glass coating system is applied to carbon-carbon composite structures, comprising a boron slurry with a specific glass mixture and a silicon slurry, each with distinct viscosity-temperature profiles, forming a multi-layered oxidation protection system that seals cracks and defects across a wide temperature range from 800°F to 1800°F.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single ceramic coating is used for oxidation protection, then it performs well within a specific temperature range, but it degrades quickly outside that range
Solution Approach 1:
The coating system is divided into multiple discrete layers, each optimized for specific temperature ranges. The first glass composition handles lower temperatures while the second glass composition handles higher temperatures, allowing each layer to specialize rather than requiring a single coating to perform all functions
Solution Approach 2:
The invention uses composite glass compositions with different chemical makeups and viscosity-temperature profiles. By combining glass compositions with silicates, borates, phosphates, and other oxides in specific ratios, the coating achieves properties that neither component alone could provide, enabling broad temperature range protection
2Object-affected harmful factors
If ceramic coatings are used to protect carbon-carbon composites, then oxidation resistance is improved, but the brittle nature of ceramics limits the operating temperature range
Solution Approach 1:
The invention changes the physical and chemical parameters of the glass coatings, specifically their viscosity-temperature profiles and softening points. By selecting glass compositions with appropriate transition temperatures and viscosities, the coating remains flexible and crack-resistant across a broad temperature spectrum from 800°F to 1800°F
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides enhanced protection against oxidation, extending the service life of carbon-carbon composite components, reducing maintenance and production costs, and minimizing carbon footprint by maintaining structural integrity across varying temperatures.
Implementation Method 1
the first glass compound having a first viscosity-temperature profile that is at least one order of magnitude below a second viscosity-temperature profile of the second glass compound
Implementation Method 2
forming a multi-layered oxidation protection system that seals cracks and defects across a wide temperature range from 800°F to 1800°F
Data Source
Figure 1
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Figure 3A~3C
AI summary
A method (200) for forming an oxidation protection system on a carbon-carbon composite structure can comprise applying a boron slurry to the carbon-carbon composite structure, wherein the boron slurry comprises a boron compound, a first glass mixture, a first glass former, a first glass modifier, and a first carrier fluid, the first glass mixture including a first glass compound and a second glass compound, the first glass compound having a first viscosity-temperature profile that is at least one order of magnitude below a second viscosity-temperature profile of the second glass compound; applying a silicon slurry to the carbon-carbon composite structure, wherein the silicon slurry comprises a silicon compound, a third glass compound, a second glass former, a second glass modifier, and a second carrier fluid; and heating the carbon-carbon composite structure.