A coating for an article includes a seal coat comprising self-healing particles disposed in a seal coat matrix and a bond coat disposed on the seal coat. The bond coat includes a matrix, diffusive particles disposed in the matrix, and gettering particles disposed in the matrix. A coating for an article and a method of applying a coating to an article are also disclosed.

A method of making spherical gettering particles for an environmental barrier coating according to an exemplary embodiment of this disclosure, among other possible things includes spraying liquid preceramic polymer into a chamber via a nozzle to form liquid droplets, curing the liquid droplets to form spherical particles in the chamber, and converting the spherical particles to spherical ceramic gettering particles in a fluidized bed. A method of making spherical gettering particles for an environmental barrier coating and an article are also disclosed.

An aerospace mirror having a reaction bonded (RB) silicon carbide (SiC) mirror substrate, and a SiC cladding on the RB SiC mirror substrate forming an optical surface on a front side of the aerospace mirror. A method for manufacturing an aerospace mirror comprising obtaining a green mirror preform comprising porous carbon, silicon carbide (SiC), or both, the green mirror preform defining a front side of the aerospace mirror and a back side of the aerospace mirror opposite the front side; removing material from the green mirror preform to form support ribs on the back side; infiltrating the green mirror preform with silicon to create a reaction bonded (RB) SiC mirror substrate from the green mirror preform; forming a mounting interface surface on the back side of the aerospace mirror from the RB SiC mirror substrate, and forming a reflector surface of the RB SiC mirror substrate on the front side of the aerospace mirror. Additionally, the method can comprise cladding the reflector surface of the RB SiC mirror substrate with SiC to form an optical surface of the aerospace mirror.

The present invention discloses novel methods for producing highly porous ceramic and/or metal aerogel monolithic objects that are hard, sturdy, and resistant to high temperatures. These methods comprise preparing nanoparticulate oxides of metals and/or metalloids via a step of vigorous stirring to prevent gelation, preparing polymer-modified xerogel powder compositions by reacting said nanoparticulate oxides with one or more polyfunctional monomers, compressing said polymer-modified xerogel powder compositions into shaped compacts, and carbothermal conversion of the shaped xerogel compacts via pyrolysis to provide the highly porous ceramic and/or metal aerogel monolithic objects that have the same shapes as to their corresponding xerogel compact precursors. Representative of the highly porous ceramic and/or metal aerogel monolithic objects of the invention are ceramic and/or metal aerogels of Si, Zr, Hf, Ti, Cr, Fe, Co, Ni, Cu, Ru, Au, and the like. Examples include sturdy, shaped, highly porous silicon carbide (SiC), silicon nitride (Si.sub.3N.sub.4), zirconium carbide (ZrC), hafnium carbide (HfC), chromium carbide (Cr.sub.3C.sub.2), titanium carbide (TiC), zirconium boride (ZrB.sub.2), hafnium boride (HfB.sub.2), and metallic aerogels of iron (Fe), nickel (Ni), cobalt (Co), copper (Cu), ruthenium (Ru), gold (Au), and the like. Said aerogel monolithic objects have utility in various applications such as, illustratively, in abrasives, in cutting tools, as catalyst support materials such as in reformers and converters, as filters such as for molten metals and hot gasses, in bio-medical tissue engineering such as bone replacement materials, in applications requiring strong lightweight materials such as in automotive and aircraft structural components, in ultra-high temperature ceramics, and the like.

An article includes a substrate and a bond coat disposed on the substrate. The bond coat includes a matrix, a plurality of gettering particles disposed in the matrix, a plurality of diffusive particles disposed in the matrix, a radiation-absorbing component disposed in the matrix, wherein the radiation-absorbing component is concentrated at an outer surface of the bond coat. An article and a method of protecting an article are also disclosed.

Methods and systems are provided for filling cracks in an environmental barrier coating and/or a thermal barrier coating (EBC/TBC). The method comprises locating a component within an enclosure of an apparatus, the component including a substrate having the EBC/TBC thereon, wherein the EBC/TBC includes cracks extending from an exterior surface of the EBC/TBC toward the substrate, reducing pressure within the enclosure to a first pressure that is less than atmospheric pressure, applying a filler slurry to the exterior surface to cover the cracks while the EBC/TBC is exposed to the first pressure, increasing the enclosure to a second pressure that is greater than the first pressure, wherein the second pressure is sufficient to cause the filler slurry on the EBC/TBC to infiltrate into and fill the cracks, and sintering the filler slurry sufficient to cure the filler slurry within the cracks.

A barrier layer for an article according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat comprising a matrix, diffusive particles disposed in the matrix, and gettering particles disposed in the matrix. The composition of the gettering particles is a reaction product of the chemical reaction of Equation 1 defined by Equation 2:

[00001]$\begin{array}{cc}{\mathrm{Si}}_w{O}_x{C}_y{N}_z+?O_2=w\mathrm{Si}{O}_2+y\mathrm{CO}+\frac{z}{2}{N}_2& \mathrm{Equation}1\end{array}$$\begin{array}{cc}?=\frac{2w+y-x}{2}& \mathrm{Equation}2\end{array}$

A barrier layer is also disclosed.

A skin assembly that includes a first ceramic-matrix-composite skin panel including one or more first fingers extending along a first direction. The skin assembly further includes a second ceramic-matrix-composite skin panel including one or more second fingers extending along the first direction. The one or more second fingers interdigitated with the one or more first fingers to define a plurality of staggered expansion gaps between the first ceramic-matrix-composite skin panel and the second ceramic-matrix-composite skin panel wherein the plurality of staggered expansion gaps are configured to accommodate thermal expansion of at least a portion of the skin assembly.

The present disclosure provides methods related to infiltration of aircraft brake discs with titanium-containing compounds. In various embodiments, a method of making a self-coating carbon/carbon composite member may comprise infiltrating a carbonized fiber preform with a titanium-containing compound, drying the carbonized fiber preform, annealing the carbonized fiber preform at a third temperature, and densifying the carbonized fiber preform.

Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided.