Encapsulated Arrays With Barrier Layer Covered Tiles

Abstract

Encapsulated arrays with tiles covered with a barrier layer are disclosed. Tiles formed of silicon carbide, and wrapped with a barrier layer, are encapsulated with a base metal formed of a steel alloy. During a casting process, to fabricate the encapsulated arrays, the barrier layer prevents the steel alloy and/or the silicon carbide from compromising each other.

1 . (canceled) 
     
     
         2 . A composite component comprising:
 a ceramic tile;   a barrier layer encapsulating the ceramic tile, the barrier layer comprising:
 a compressible layer comprising alumina fiber encapsulating the ceramic tile; and 
 a refractory layer comprising a metal film encapsulating the alumina fiber encapsulating the ceramic tile; 
   a steel alloy encapsulating the barrier layer and the ceramic tile; and   wherein the alumina fiber dampens a compression force applied by the steel alloy to provide crush protection between the steel alloy and the ceramic tile, and the refractory layer prevents the steel alloy from reacting with the ceramic tile.   
     
     
         3 . The composite component of  claim 2 , wherein the compressible layer provides crush protection between the steel alloy and the ceramic tile during a cooling of the steel alloy. 
     
     
         4 . The composite component of  claim 1 , wherein the steel alloy comprises 4140 AISI steel, 8630 AISI steel, or FeMnAl. 
     
     
         5 . The composite component of  claim 2 , wherein the metal film comprises a powder coat, and the powder coat encapsulates the compressible layer and the ceramic tile. 
     
     
         6 . The composite component of  claim 2 , wherein the metal film comprises a paint coating, and the paint coating encapsulates the compressible layer and the ceramic tile. 
     
     
         7 . The composite component of  claim 2 , wherein the ceramic tile comprises silicon carbide. 
     
     
         8 . The composite component of  claim 2 , wherein the metal film has a thickness of at least about 0.001 inches (0.002 centimeters), and at most about 0.009 inches (0.02 centimeters). 
     
     
         9 . The composite component of  claim 2 , wherein the compressible layer has a thickness of at least about 0.05 inches (0.13 centimeters), and at most about 0.06 inches (0.15 centimeters). 
     
     
         10 . A composite component comprising:
 an array of ceramic tiles comprising:   a first layer, encapsulating each ceramic tile of the array of ceramic tiles, to prevent a steel alloy from reacting with the respective ceramic tile of the array of ceramic tiles during a casting of the steel alloy around the array of solid ceramic tiles; and   a second layer, disposed between the first layer and each ceramic tile, the second layer to dampen a compression force applied by the steel alloy to provide crush protection between the steel alloy and each solid ceramic tile during a cooling of the composite component; and   the steel alloy encapsulating the array of solid ceramic tiles.   
     
     
         11 . The composite component of  claim 11 , wherein each ceramic tile comprises silicon carbide. 
     
     
         12 . The composite component of  claim 11 , wherein the first layer comprises metal film and the second layer comprises alumina fiber. 
     
     
         13 . The composite component of  claim 12 , wherein the metal film comprises a powder coat, and the powder coat encapsulates the alumina fiber and the ceramic tile. 
     
     
         14 . The composite component of  claim 12 , wherein the metal film comprises a paint coating, and the paint coating encapsulates the alumina fiber and the ceramic tile. 
     
     
         15 . The composite component of  claim 12 , wherein the metal film has a thickness of at least about 0.001 inches (0.002 centimeters), and at most about 0.009 inches (0.02 centimeters). 
     
     
         16 . The composite component of  claim 11 , wherein the second layer has a thickness of at least about 0.05 inches (0.13 centimeters), and at most about 0.06 inches (0.15 centimeters). 
     
     
         17 . A composite component comprising:
 a plurality of ceramic tiles arranged substantially in a same plane;   a barrier layer encapsulating each ceramic tile of the plurality of ceramic tiles, the barrier layer comprising:
 a compressible layer comprising alumina fiber encapsulating the ceramic tile; and 
 a refractory layer comprising a metal film encapsulating the alumina fiber encapsulating the ceramic tile; 
   a steel alloy encapsulating the barrier layer and each ceramic tile of the plurality of ceramic tiles; and   wherein the alumina fiber dampens a compression force applied by the steel alloy to provide crush protection between the steel alloy and the ceramic tile, and the refractory layer prevents the steel alloy from reacting with the ceramic tile.   
     
     
         18 . The composite component of  claim 17 , wherein the plurality of ceramic tiles are arranged substantially adjacent to one another. 
     
     
         19 . The composite component of  claim 17 , wherein the steel alloy comprises 4140 or 8630 AISI steel. 
     
     
         20 . The composite component of  claim 17 , wherein the steel alloy comprises FeMnAl. 
     
     
         21 . The composite component of  claim 17 , wherein at least one of the plurality of ceramic tiles comprises silicon carbide.