Granted Patent B2

US 12,311,574 · App. 17/401,721 · Granted May 27, 2025

Inventors: Xuan Liu (Glastonbury, CT); James T. Beals (West Hartford, CT); Xia Tang (West Hartford, CT); Justin R. Hawkes (Marlborough, CT); Olivier H. Sudre (Glastonbury, CT); William F. Werkheiser (East Hartford, CT); Brian T. Hazel (Avon, CT); Richard Wesley Jackson (Mystic, CT)

Assignee: RTX CORPORATION

B28B23/0056B28B1/24B28B7/0008B28B7/06B28B7/348B28B19/00B28B23/0068B29C33/405B29C37/0028C04B41/0009C04B41/45C04B41/4539C04B41/4578B29C2037/0035C04B41/87F01D5/147F01D5/282F01D5/284F01D5/288F05D2230/211F05D2230/51F05D2230/90F05D2300/6033

Abstract

Claims (17)

1. A method of forming a coating, comprising:

providing a mold that has a flexible wall formed of silicone elastomer that defines a mold cavity;

inserting a component that is to be coated into the mold cavity, the component having a component surface roughness and there being a coating gap defined between the component and the flexible wall of the mold cavity;

introducing a molding slurry into the mold cavity, the molding slurry including a carrier liquid and powder particles, the molding slurry filling the coating gap and contacting the component so as to overcoat the component surface roughness;

solidifying the molding slurry to form a green coating of powder particles on the component; and

consolidating the green coating to form a final coating on the component, the final coating having a coating surface roughness that is less than the component surface roughness.

2. The method as recited in claim 1 , wherein the inserting includes situating the component in the mold cavity such that the coating gap is of uniform thickness.

3. The method as recited in claim 1 , wherein the inserting includes using one or more bumpers in the mold cavity to space the component from the flexible wall.

4. The method as recited in claim 3 , wherein the component has one or more cooling holes, and the one or more bumpers plug the one or more cooling holes.

5. The method as recited in claim 1 , wherein the component has a cooling hole that is plugged.

6. The method as recited in claim 1 , wherein the solidifying includes heating the molding slurry while in the coating gap in the mold cavity.

7. The method as recited in claim 1 , wherein the mold includes at least one injection port and at least one vent port.

8. The method as recited in claim 1 , wherein the consolidating includes heating the green coating to a temperature at which the powder particles sinter.

9. The method as recited in claim 1 , wherein the mold is formed of elastomer.

10. The method as recited in claim 1 , wherein the component is a gas turbine engine component formed of ceramic matrix composite.

11. The method as recited in claim 8 , wherein the component is a ceramic matrix composite.

12. The method as recited in claim 11 , wherein the powder particles include at least one of silica particles or siliconoxycarbide particles.

Assignments (2)

Continuity (2)

References Cited (23)