IP Library › Granted Patent US 12,668,550
Granted Patent B2
US 12,668,550 · App. 18/202,036 · Granted Jun 30, 2026

Multilayer coating for oxidation protection

Inventors: Olivier H. Sudre (Glastonbury, CT); Evan B. Callaway (Santa Barbara, CA); Daniel L. Becerra (West Hartford, CT); Mary Colby (West Hartford, CT); Cristal Chan (East Hampton, CT)
Assignee: RTX Corporation
C04B35/80C04B35/62863C04B35/62868C04B35/62871C04B35/62873C04B35/62876C04B35/62878C04B35/62894C04B35/62897C04B2235/3826C04B2235/5244
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Quick Facts
Patent No.
US 12,668,550
App. No.
18/202,036
Granted
Jun 30, 2026
Kind
B2
Abstract

A coated fiber structure for use in a ceramic matrix composite comprises a fiber and a coating system applied to and circumscribing the fiber. The coating system comprises an interface coating layer in direct contact with the fiber, the interface coating layer comprising one of boron nitride and a boron-doped pyrocarbon, at least one intermediate layer extending coaxially with and in direct contact with the interface layer, the at least one intermediate layer comprising at least one of silicon and boron nitride, and an outer layer extending coaxially with and in direct contact with the interface layer. At least one of the interface coating layer, the at least one intermediate layer, and the outer layer comprises a metallic element.

Claims (32)

1 . A coated fiber structure for use in a ceramic matrix composite, the coated fiber structure comprising:

a fiber; and

a coating system applied to and circumscribing the fiber, the coating system comprising:

an interface coating layer in direct contact with the fiber, the interface coating layer comprising one of boron nitride and a boron-doped pyrocarbon;

a first intermediate layer extending coaxially with and in direct contact with the interface coating layer, the first intermediate layer comprising silicon carbide;

a second intermediate layer in direct contact with the first intermediate layer, wherein the second intermediate layer comprises boron nitride;

a third intermediate layer in direct contact with the second intermediate layer, wherein the third intermediate layer comprises silicon-doped boron nitride; and

an outer layer extending coaxially with and in direct contact with the third intermediate layer;

wherein at least one of the interface coating layer, the first intermediate layer, the second intermediate layer, the third intermediate layer, and the outer layer comprises a metallic element.

2 . The fiber structure of claim 1 , wherein the fiber is formed from silicon carbide.

3 . The fiber structure of claim 1 , wherein the metallic element is selected from the group consisting of zirconium, hafnium, rare earth metals, and combinations thereof.

4 . The fiber structure of claim 3 , wherein the metallic element is formed as one of a carbide and a nitride.

5 . The fiber structure of claim 3 , wherein the outer layer comprises the metallic element.

6 . The fiber structure of claim 3 , wherein one of the interface coating layer, the first intermediate layer, the second intermediate layer, and the third intermediate layer comprises the metallic element.

7 . The fiber structure of claim 1 , wherein the second intermediate layer comprises the metallic element, and wherein the metallic element is selected from the group consisting of zirconium, hafnium, rare earth metals, and combinations thereof.

8 . The fiber structure of claim 7 , wherein the outer layer comprises silicon nitride.

9 . The fiber structure of claim 1 , wherein the outer layer comprises the metallic element, and wherein the metallic element is selected from the group consisting of zirconium, hafnium, rare earth metals, and combinations thereof.

10 . The fiber structure of claim 1 , wherein each of the interface coating layer, the first intermediate layer, the second intermediate layer, the third intermediate layer, and the outermost layer has a thickness ranging from 20 nm to 1.0 micron.

11 . A ceramic matrix composite comprising:

a plurality of ceramic fibers;

a coating system applied to and circumscribing each fiber of the plurality of fibers,

the coating system comprising:

an interface coating layer in direct contact with the fiber, the interface coating layer comprising one of boron nitride and a boron-doped pyrocarbon;

a first intermediate layer extending coaxially with and in direct contact with the interface coating layer, the at least one intermediate layer comprising silicon carbide;

a second intermediate layer in direct contact with the first intermediate layer, wherein the second intermediate layer comprises boron nitride;

a third intermediate layer in direct contact with the second intermediate layer, wherein the third intermediate layer comprises silicon-doped boron nitride; and

an outer layer extending coaxially with and in direct contact with the third intermediate layer;

wherein at least one of the interface coating layer, the first intermediate layer, the second intermediate layer, the third intermediate layer, and the outer layer comprises a metallic element; and

a matrix deposited on the plurality of fibers and the coating system.

12 . The composite of claim 11 , wherein the matrix is formed from silicon carbide.

13 . The composite of claim 11 , wherein the outer layer comprises the metallic element.

14 . The composite of claim 13 , wherein the metallic element is selected from the group consisting of zirconium, hafnium, rare earth metals, and combinations thereof.