Tile for fabrication and repair of thermal barriers

Abstract

A thermal barrier tile ( 34 ) with a braze layer ( 46 ) co-sintered to a ceramic layer ( 48 ), optionally with a layer of MCrAlY bond material ( 74 ) disposed there between. The tile can be brazed to a substrate ( 26 ) of a component for fabrication or repair of a thermal barrier coating ( 28 ). The tile may be fabricated by disposing a first layer of a metal brazing material in a die case ( 40 ); disposing a second layer of a ceramic powder on the metal brazing material; and co-sintering the two layers with spark plasma sintering to form the co-sintered ceramic/metal tile. The tile may include an interlocking structural pattern ( 56 ) at the ceramic/braze interface, and further may include mirror image contoured edges ( 70 ) for interlocking of tiles that are disposed side-by-side. Heights of adjacent tiles ( 34 F, 34 G) may be different to improve abradability of the surface.

The invention claimed is: 
     
         1 . A thermal barrier tile, comprising:
 a layer of a brazing material;   a layer of a ceramic thermal barrier material; and   a co-sintered interface between the brazing material and the ceramic thermal barrier material.   
     
     
         2 . The thermal barrier tile of  claim 1 , further comprising:
 a first non-planar side surface on a first side;   a second non-planar side surface on a second side opposed the first side, wherein shapes of the first and second non-planar side surfaces are complementary mirror images such that when a pair of such thermal barrier tiles are disposed side-by-side, the tiles interlock.   
     
     
         3 . The thermal barrier tile of  claim 1 , wherein a top surface of the layer of ceramic thermal barrier material comprises a predetermined pattern of ridges and depressions. 
     
     
         4 . The thermal barrier tile of  claim 1 , wherein the interface comprises a non-planar pattern. 
     
     
         5 . The thermal barrier tile of  claim 1 , wherein the layer of ceramic thermal barrier material comprises a gradient porosity that increases toward a top surface thereof. 
     
     
         6 . The thermal barrier tile of  claim 1 , further comprising a layer of MCrAIY bond material disposed between the layer of brazing material and the layer of ceramic thermal barrier material. 
     
     
         7 . The thermal barrier tile of  claim 1 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 15-25%;   Ti 15-25%;   balance Ni.   
     
     
         8 . The thermal barrier tile of  claim 7 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 16.3%;   Ti 21.2%;   balance Ni.   
     
     
         9 . The thermal barrier tile of  claim 7 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 17.2%;   Ti 20.9%;   balance Ni.   
     
     
         10 . The thermal barrier tile of  claim 1 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 12-16%;   Ti 13-16%;   Al 0-2.5%;   Co 2-4%;   W 3-5%;   Mo 0-2%;   Ta 0-2%;   balance Ni.   
     
     
         11 . The thermal barrier tile of  claim 10 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 14.1%;   Ti 14%;   Al 2.1%;   Co 3.1%;   W 4.1%;   Mo 1%   Ta 1%;   balance Ni.   
     
     
         12 . The thermal barrier tile of  claim 1 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 15-18%;   Ti 10-15%;   Al 0-2.5%;   Co 2-4%;   W 3-5%;   Mo 0-2%;   Ta 0-2%;   balance Ni.   
     
     
         13 . The thermal barrier tile of  claim 12 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 17.57%;   Ti 13.54%;   Al 2.39%;   Co 3.24%;   W 3.47%;   Mo 1.15%;   Ta 0.83%;   balance Ni.   
     
     
         14 . The thermal barrier tile of  claim 1 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 15-19%;   Ti 8-10%;   Al 0-2.5%;   Co 14-18%;   Mo 12-16%;   balance Ni.   
     
     
         15 . The thermal barrier tile of  claim 14 , wherein the layer of brazing material comprises (in units of wt. %):
 Cr 15.12%;   Ti 10%;   Al 2.12%;   Co 15.8%;   Mo 12.97%;   balance Ni.   
     
     
         16 . The thermal barrier tile of  claim 1 , wherein the layer of brazing material comprises (in units of wt. %):
 0-2.5% Al;   14-18% Co;   15-19% Cr;   12-16% Mo;   8-10% Ti;   balance Ni.   
     
     
         17 . An apparatus comprising:
 a substrate;   at least a portion of a surface of the substrate covered by a thermal barrier tile, the thermal barrier tile comprising:   a layer of ceramic thermal barrier material; and   a layer of braze material joining the layer of ceramic thermal barrier material to the substrate.   
     
     
         18 . The apparatus of  claim 17 , further comprising:
 a depression formed in the substrate;   the thermal barrier tile disposed in the depression.   
     
     
         19 . The apparatus of  claim 17 , further comprising a plurality of the thermal barrier tiles covering the portion of the surface of the substrate; and
 complementary mirror image contoured edges formed on respective adjacent ones of the thermal barrier tiles.   
     
     
         20 . The apparatus of  claim 17 , further comprising a plurality of the thermal barrier tiles covering the portion of the surface of the substrate; and
 a thickness of adjacent ones of the thermal barrier tiles being different to form a surface pattern.