Silicon-Based Materials Containing Indium and Methods of Forming the Same

Abstract

A ceramic component is generally provided that includes a silicon-based layer comprising a silicon-containing material (e.g., a silicon metal and/or a silicide) and about 0.001% to about 85% of an In-containing compound. For example, the silicon-based layer can be a bond coating directly on the surface of the substrate. Alternatively or additionally, the silicon-based layer can be an outer layer defining a surface of the substrate, with an environmental barrier coating on the surface of the substrate. Gas turbine engines are also generally provided that include such a ceramic component.

What is claimed is: 
     
         1 . A ceramic component comprising: a silicon-based layer comprising a silicon-containing material and about 0.001% to about 85% of an In-containing compound. 
     
     
         2 . The ceramic component as in  claim 1 , comprising: a substrate defining a surface, wherein the silicon-based layer is a bond coating directly on the surface of the substrate. 
     
     
         3 . The ceramic component as in  claim 2 , wherein the silicon-containing material is silicon metal. 
     
     
         4 . The ceramic component as in  claim 3 , wherein a thermally grown oxide is on the bond coating, and wherein the thermally grown oxide layer remains amorphous up to an operating temperature of about 1415° C. or less. 
     
     
         5 . The ceramic component as in  claim 2 , wherein the silicon-containing material comprises a silicide. 
     
     
         6 . The ceramic component as in  claim 5 , wherein a thermally grown oxide is on the bond coating, and wherein the thermally grown oxide layer remains amorphous up to an operating temperature of about 1485° C. or less. 
     
     
         7 . The ceramic component as in  claim 5 , wherein the silicide comprises molybdenum silicide, rhenium silicide, a rare earth silicide, or a mixture thereof. 
     
     
         8 . The ceramic component as in  claim 1 , wherein the ceramic component comprising: a substrate, wherein the silicon-based layer is an outer layer defining a surface of the substrate; and an environmental barrier coating on the surface of the substrate. 
     
     
         9 . The ceramic component as in  claim 8 , wherein the substrate comprises the outer layer on a plurality of CMC plies, and wherein the outer layer comprises silicon carbide. 
     
     
         10 . The ceramic component as in  claim 1 , wherein the In-containing compound comprises a compound having a formula:
   Ln 2-x-y Ga x In y Si 2 O 7      where   Ln is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, or a mixture thereof;   x is 0 to about 1; and   y is greater than 0 to about 1.   
     
     
         11 . The ceramic component as in  claim 1 , wherein the In-containing compound comprises a compound having a formula:
   Ln 2-x-y Ga x In y Si 2 O 5      where Ln is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, or a mixture thereof;   x is 0 to about 1; and y   is greater than 0 to about 1.   
     
     
         12 . The ceramic component as in  claim 1 , wherein the In-containing compound comprises a compound having a formula:
   Ln 3 In 5-x M x O 12      where   Ln is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, or a mixture thereof, and   M is Ga with 0≤x<5, Al with 0≤x<5, Fe with 0≤x<5, B with 0≤x≤2.5, or a combination thereof.   
     
     
         13 . The ceramic component as in  claim 12 , where x is 0.1 to about 2. 
     
     
         14 . The ceramic component as in  claim 12 , where M is B; and x is 0.1 to about 2. 
     
     
         15 . The ceramic component as in  claim 1 , wherein the In-containing compound comprises InN. 
     
     
         16 . A gas turbine engine comprising the ceramic component of  claim 1 .