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Multilayer ytterbium-hafnate/silicate coatings deposited by directed vapor deposition and designed to protect SiC-based ceramic matrix composites were assessed to determine their thermochemical stability and resistance to attack by molten silicate deposits (CMAS). The study revealed that reactions occurring at the interface between Yb 2 Si 2 O 7 and Yb 4 Hf 3 O 12 layers promote coating delamination following isothermal annealing for 100 h/1500°C while coating architectures involving Yb 2 SiO 5 in contact with Yb 4 Hf 3 O 12 do not experience similar degradation. The outer Yb 4 Hf 3 O 12 layers, segmented for compliance, were only moderately effective in mitigating CMAS infiltration at 1300°C and 1500°C. The results indicate that the reaction between the melt and coating forms large volumes of a silicate garnet phase at 1300°C, or a cuspidine-type aluminosilicate at 1500°C, in addition to the apatite and reprecipitated fluorite phases observed in related systems.

Low-density, open-cell nickel base superalloy foams have been synthesized by a high-rate, electron beam-directed vapor deposition process and their mechanical properties evaluated. The deposition process uses an open-cell polymer foam template upon which is deposited a metal alloy coating. The electron beam evaporated flux was entrained in a rarefied transonic gas jet and propagated along the flow stream lines through the polymer structure. After vapor deposition, the polymer template was removed by low-temperature thermal decomposition. The resultant ultralightweight metal foams consisted of a three-dimensional open cell, reticulated structure possessing hollow triangular ligaments with relative densities of <3%. Their mechanical integrity was increased by either pressureless or transient liquid phase sintering. The mechanical properties of these ultralightweight metal foams were comparable to theoretical predictions for open-cell, reticulated foams.

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