Composite components for use in high temperature applications

Abstract

Fibrous monolith composites suitable for use in high temperature environments and/or harsh chemical environments are provided, along with methods of preparation thereof. The fibrous monolith composites exhibit such beneficial properties as enhanced strength, corrosion resistance, thermal shock resistance and thermal cycling tolerance.

1 . A method of manufacturing a high temperature fibrous monolith composite comprising: 
 blending a first composition of one or more powders with a processing compound to provide a core material;    blending a second composition of one or more powders with a processing compound to provide an intermediate shell material;    blending a third composition of one or more powders with a processing compound to provide an outer shell material;    forming a feed rod from the core material, intermediate shell material and outer shell material;    extruding the formed feed rod to create a reduced diameter filament; and    sintering the filament to provide the high temperature fibrous monolith composite,    the core material and intermediate and outer shell materials being generally discrete in the composite and each composition being selected from the group consisting of materials that remain in the solid state to allow use of the composite at an operating temperature of at least about 1000° C. or more.    
   
   
       2 . The method of  claim 1 , wherein at least one of the first composition, second composition and third composition includes a powder selected from the group consisting of metal, metal alloy, carbide, nitride, boride, oxide, phosphate and silicide and combinations thereof.  
   
   
       3 . The method of  claim 1 , wherein the processing compound includes a polymer binder and wherein the polymer binder is removed from the filament after extrusion.  
   
   
       4 . The method of  claim 1  further including: 
 consolidating two or more reduced diameter filaments to create a multi-filament rod; and    extruding the multi-filament rod to create a reduced diameter second filament.    
   
   
       5 . An article of manufacture suitable for use in a high temperature environment comprising fibrous monolith composite materials, fibrous monolith composite materials comprising: 
 a first composition selected from the group consisting of metal, metal alloy, carbide, nitride, boride, oxide, phosphate and silicide and combinations thereof; and    a second composition generally surrounding the first composition and selected from the group consisting of metal, metal alloy, carbide, nitride, boride, oxide, phosphate and silicide and combinations thereof,    a third composition generally surrounding the first and second composition and selected from the group consisting of metal, metal alloy, carbide, nitride, boride, oxide, phosphate and silicide and combinations thereof,    the compositions being generally discrete in the composite materials and each composition being selected from the group consisting of materials that remain in the solid state to allow use of the article at an operating temperature of at least about 1000° C. or more.    
   
   
       6 . The article of  claim 5 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the article at an operating temperature of at least about 1600° C. or more.  
   
   
       7 . The article of  claim 5 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the article at an operating temperature of at least about 2500° C. or more.  
   
   
       8 . The article of  claim 5 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the article at an operating temperature of at least about 3000° C. or more.  
   
   
       9 . A coating material comprising fibrous monolith materials including: 
 a first composition of one or more powders selected from the group consisting of metal, metal alloy, carbide, nitride, boride, oxide, phosphate and silicide and combinations thereof and a processing compound; and    a second composition of one or more powders selected from the group consisting of metal, metal alloy, carbide, nitride, boride, oxide, phosphate and silicide and combinations thereof and a processing compound, said second composition generally surrounding the first composition,    the compositions being generally discrete in the fibrous monolith materials and each composition being selected from the group consisting of materials that remain in the solid state to allow use of the coating material at an operating temperature of at least about 1000° C. or more.    
   
   
       10 . The coating material of  claim 9 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the coating material at an operating temperature of at least about 1600° C. or more.  
   
   
       11 . The coating material of  claim 9 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the coating material at an operating temperature of at least about 2500° C. or more.  
   
   
       12 . The coating material of  claim 9 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the coating material at an operating temperature of at least about 3000° C. or more.  
   
   
       13 . The coating material of  claim 9 , including a third composition of one or more powders selected from the group consisting of metal, metal alloy, carbide, nitride, boride, oxide, phosphate and silicide and combinations thereof and a processing compound, said third composition generally surrounding the second composition.  
   
   
       14 . The coating material of  claim 13 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the coating material at an operating temperature of at least about 1600° C. or more.  
   
   
       15 . The coating material of  claim 13 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the coating material at an operating temperature of at least about 2500° C. or more.  
   
   
       16 . The coating material of  claim 13 , wherein each composition is selected from the group consisting of materials that remain in the solid state to allow use of the coating material at an operating temperature of at least about 3000° C. or more.