Granted Patent B2

US 12,415,759 · App. 18/765,864 · Granted Sep 16, 2025

Inventor: Atta Khan (Riverside, CA)

Assignee: GOODRICH CORPORATION

C04B35/10C03C8/08C04B35/62222C04B35/64C04B41/5022C04B41/86F16D65/126C03C2209/00C04B2235/3217C04B2235/3821C04B2235/3826C04B2235/3895C04B2235/402C04B2235/428C04B2235/9684F16D2200/0047F16D2250/0046

Abstract

Claims (34)

1. An oxidation protection system disposed on an outer surface of a substrate, comprising:

a ceramic layer consisting of between 50% and 94% alumina by weight between 5% and 50% aluminum nitride, pure silicon between 1% and 30% by weight, and optionally a binder having a remaining weight, wherein the ceramic layer is formed by:

preparing a ceramic layer slurry by combining only an aluminum powder and a silicon powder in a solvent or a carrier fluid, wherein the aluminum powder and the silicon powder comprise between 40% and 60% by weight of the ceramic layer slurry;

applying the ceramic layer slurry to a composite structure, wherein the ceramic layer slurry comprises the aluminum powder and the silicon powder in the solvent or the carrier fluid; and

heating the composite structure in an environment comprising nitrogen gas and oxygen gas to form the ceramic layer on the composite structure; and

a sealant layer comprising a sealant pre-slurry composition comprising a sealant phosphate glass composition.

2. The oxidation protection system of claim 1 , wherein the ceramic layer is a single continuous layer comprising the alumina and the aluminum nitride.

3. An aircraft brake disk, comprising:

a carbon-carbon composite structure comprising a non-friction surface; and

an oxidation protection system disposed on the non-friction surface, the oxidation protection system comprising:

a ceramic layer consisting of between 50% and 94% alumina by weight, between 5% and 50% aluminum nitride, pure silicon between 1% and 30% by weight, and optionally a binder having a remaining weight, wherein the ceramic layer is formed by:

preparing a ceramic layer slurry by combining only an aluminum powder and a silicon powder in a solvent or a carrier fluid, wherein the aluminum powder and the silicon powder comprise between 40% and 60% by weight of the ceramic layer slurry;

applying the ceramic layer slurry to a composite structure, wherein the ceramic layer slurry comprises the aluminum powder and the silicon powder in the solvent or the carrier fluid; and

heating the composite structure in an environment comprising nitrogen gas and oxygen gas to form the ceramic layer on the composite structure; and

a sealant layer comprising a sealant pre-slurry composition comprising a sealant phosphate glass composition.

4. The aircraft brake disk of claim 3 , wherein the ceramic layer is a single continuous layer comprising the alumina and the aluminum nitride.

5. The oxidation protection system of claim 1 , wherein sealant layer is formed by:

preparing a sealant slurry by combining a sealant pre-slurry composition with a carrier fluid;

applying the sealant slurry to an outer surface of the ceramic layer; and

heating the composite structure to form the sealant layer over the ceramic layer.

6. The oxidation protection system of claim 5 , wherein the sealant pre-slurry composition comprises a sealant phosphate glass composition in glass frit form.

7. The oxidation protection system of claim 5 , wherein the sealant pre-slurry composition comprises a sealant phosphate glass composition in powder form.

8. The oxidation protection system of claim 5 , wherein the sealant pre-slurry composition further comprises ammonium dihydrogen phosphate.

9. The oxidation protection system of claim 5 , wherein the sealant pre-slurry composition further comprises aluminum orthophosphate.

10. The oxidation protection system of claim 5 , wherein the carrier fluid is water.

11. The aircraft brake disk of claim 3 , wherein sealant layer is formed by:

preparing a sealant slurry by combining a sealant pre-slurry composition with a carrier fluid;

applying the sealant slurry to an outer surface of the ceramic layer; and

heating the composite structure to form the sealant layer over the ceramic layer.

12. The aircraft brake disk of claim 11 , wherein the sealant pre-slurry composition comprises a sealant phosphate glass composition in glass frit form.

13. The aircraft brake disk of claim 11 , wherein the sealant pre-slurry composition comprises a sealant phosphate glass composition in powder form.

14. The aircraft brake disk of claim 11 , wherein the sealant pre-slurry composition further comprises ammonium dihydrogen phosphate.

15. The aircraft brake disk of claim 11 , wherein the sealant pre-slurry composition further comprises aluminum orthophosphate.

16. The aircraft brake disk of claim 11 , wherein the carrier fluid is water.

Assignments (1)

Continuity (2)

References Cited (400)