High temperature erosion resistant coating and material containing compacted hollow geometric shapes

Abstract

A method for making a material system includes the steps of: providing a chamber, placing hollow geometric shapes in the chamber, closing the chamber, evacuating air from the chamber, feeding a binder for the shapes into the evacuated chamber to impregnate the geometric shapes, drying the binder permeated geometric shapes, and heating the hollow shapes and binder to provide a unitary, sintered material system.

1 - 12 . (canceled)  
     
     
         13 - 15 . (canceled)  
     
     
         16 - 18 . (canceled)  
     
     
         19 - 20 . (canceled)  
     
     
         21 . A material system for use in a high temperature environment in excess of approximately 1 300° C., comprising: 
 a plurality of generally contacting dimensionally stable geometric shapes having an oxide based composition, the shapes being close packed with void spaces therebetween such that a substantial number of the shapes contact at least 1 adjacent other shape, the dimensionally stable geometric shapes formed at a stabilizing temperature that causes the shapes to not sinter to one another at a temperature at which the geometric shapes would sinter together prior to stabilization; and    a binder material coating at least a portion of the geometric shapes,    whereby heating the coated geometric shapes to at least 400° C. forms the material system adapted for use in the high temperature environment in excess of approximately 1300° C.    
     
     
         22 . The material system of  claim 21 , wherein the geometric shapes are hollow, and achieve dimensionally stability by being preheated to a temperature in excess of 1600° C.  
     
     
         23 . The material system of  claim 21 , wherein the binder material is in a slurry form when used to coat the geometric shapes.  
     
     
         24 - 28 . (canceled)  
     
     
         29 . A material for use in a high temperature environment at a use temperature, the material comprising: 
 a packed plurality of geometric shapes defining spaces there between, the geometric shapes being individually formed at a manufacturing temperature sufficiently high so that the geometric shapes remain stable and do not sinter together during manufacturing of the material or when the material is operated at the use temperature; and    a binder material holding the geometric shapes together.    
     
     
         30 . The material of  claim 29 , wherein the geometric shapes comprise spheres having sphere walls of 70-100% theoretical density.  
     
     
         31 . The material system of  claim 21 , wherein the binder material comprises an aluminum phosphate based composition.  
     
     
         32 . The material system of  claim 21 , wherein the geometric shapes are spheres.  
     
     
         33 . The material system of  claim 21 , wherein the material system is used in a combustion turbine engine.  
     
     
         34 . The material system of  claim 21 , wherein the material system is used with a component selected from the group consisting of: blade, vane, combustor and shroud seal.  
     
     
         35 . The material of  claim 29 , wherein the binder material comprises an aluminum phosphate based composition.  
     
     
         36 . The material of  claim 29 , wherein the material is used in a combustion turbine engine.  
     
     
         37 . The material of  claim 29 , wherein the material is used with a component selected from the group consisting of: blade, vane, combustor and shroud seal.