Method to protect features during repair cycle

Patent metadata

Field	Value
Publication number	US-10030305-B2
Application number	US-201514945824-A
Country	US
Kind code	B2
Filing date	Nov 19, 2015
Priority date	Nov 19, 2015
Publication date	Jul 24, 2018
Grant date	Jul 24, 2018

Abstract

A method can include applying a mask to a CMC structure, and subjecting the structure having an applied mask to a process for repair. In one embodiment, the applying a mask to a CMC structure can include applying a mask to a feature of a CMC structure.

First claim

The invention claimed is:

1. A method comprising:
applying a mask to a ceramic matrix composite (CMC) structure; and
subjecting the structure having the mask to a process for repair, wherein the process for repair includes melt infiltration, wherein the applying includes applying the mask to a functional feature of the structure, and wherein the mask is adapted to inhibit flow of liquid material to the functional feature during melt infiltration.

2. The method of claim 1 , wherein the mask includes BN, and wherein the liquid material includes liquid silicon.

3. The method of claim 1 , wherein the mask includes oxide material, and wherein the liquid material includes liquid silicon.

4. A method comprising:
applying a mask to a ceramic matrix composite (CMC) structure; and
subjecting the structure having the mask to a process for repair, wherein the process for repair includes chemical vapor infiltration (CVI).

5. The method of claim 4 , wherein the mask includes vaporization resistant material.

6. The method of claim 4 , wherein the applying includes applying the mask to a functional feature of the structure, and wherein the mask is adapted to inhibit flow of vapor to the functional feature during chemical vapor infiltration.

7. The method of claim 6 , wherein the mask includes a metal material, and wherein the method includes, subsequent to the subjecting, removing the mask using a chemical etching process.

8. The method of claim 6 , wherein the mask includes an oxide material, and wherein the method includes, subsequent to the subjecting, removing the mask using a chemical etching process.

9. The method of claim 6 , wherein the mask includes an oxide material, and wherein the method includes, subsequent to the subjecting, removing the mask using a wet etching agent that is inert to the CMC structure.

10. The method of claim 6 , wherein the mask includes an oxide material, and wherein the method includes removing the mask using a wet etching agent, the wet etching agent being selected from the group consisting of an acid wet etching agent and a base wet etching agent.

11. The method of claim 6 , wherein the mask includes an oxide material, and wherein the method includes removing the mask using a wet etching agent that is inert to the CMC structure, wherein the oxide material is selected from the group consisting of silicon oxide, yttrium oxide, zirconium oxide, wherein the wet etching agent is selected from the group consisting of NaOH, HF, and nitric acid.

12. The method of claim 6 , wherein the method includes removing the mask using a dry etching agent.

13. The method of claim 6 , wherein the mask includes a carbon material, and wherein the method includes removing the mask using a dry etching process.

14. The method of claim 6 , wherein the mask includes a carbon material, and wherein the method includes removing the mask using an oxidation process.

15. A method comprising:
applying a mask to a ceramic matrix composite (CMC) structure; and
subjecting the structure having the mask to a process for repair, wherein the process for repair includes a combination of two or more of the following selected from the group consisting of melt infiltration (MI), chemical vapor infiltration (CVI), and polymer impregnation and pyrolysis (PIP).

16. The method of claim 1 , wherein the mask comprises a material that is resistant to wetting by a liquid in the process for repair selected from the group consisting of material including nitride and material including oxide.

17. The method of claim 16 , wherein the wetting resistant material is selected from the group consisting of material including boron nitride and material including silicon dioxide.

18. The method of claim 1 , wherein the mask includes material that is thermally stable under process conditions of the process for repair.

19. The method of claim 1 , further comprising:
using subtractive processing to remove accumulations from the structure.

20. The method of claim 1 , wherein the functional feature is selected from the group consisting of cooling holes, attachment holes, mounting holes, sealing surfaces, and slots.

21. The method of claim 1 , wherein the mask is adapted to be friable, and wherein the method includes removing the mask using a mechanical process.

22. The method of claim 1 , wherein the mask is adapted to be chemically etched, and wherein the method includes removing the mask using a chemical etching agent.

23. The method of claim 1 , wherein the applying a mask includes applying the mask so that an area of the mask is included within an interior defined by a feature of the structure.

24. The method of claim 1 , wherein the mask is adapted to be chemically inert so that the mask is resistant to chemically bonding with the structure.

25. The method of claim 1 , wherein the mask includes boron nitride slurry with a polyethylenimine (PEI) dispersant.

26. The method of claim 1 , wherein the mask is adapted for oxidative removal, and wherein the method includes oxidative removal of the mask.

27. The method of claim 1 , wherein the process for repair includes application of heat and wherein the method includes applying the mask to a functional feature of the CMC structure.

28. The method of claim 4 , further comprising:
using subtractive processing to remove accumulations from the structure.

29. The method of claim 6 , wherein the functional feature is selected from the group consisting of cooling holes, attachment holes, mounting holes, sealing surfaces, and slots.

30. The method of claim 6 , wherein the mask is adapted to be friable, and wherein the method includes removing the mask using a mechanical process.

31. The method of claim 6 , wherein the mask is adapted to be chemically etched, and wherein the method includes removing the mask using a chemical etching agent.

32. The method of claim 6 , wherein the applying a mask includes applying the mask so that an area of the mask is included within an interior defined by a feature of the structure.

33. The method of claim 6 , wherein the mask is adapted to be chemically inert so that the mask is resistant to chemically bonding with the structure.

34. The method of claim 6 , wherein the mask includes boron nitride slurry with a polyethylenimine (PEI) dispersant.

35. The method of claim 6 , wherein the mask is adapted for oxidative removal, and wherein the method includes oxidative removal of the mask.

36. The method of claim 6 , wherein the process for repair includes application of heat and wherein the method includes applying the mask to a functional feature of the CMC structure.

Assignees

• Gen Electric

Inventors

• Weaver Jared Hogg
• Corman Gregory Scot
• Kebbede Anteneh
• Dunn Daniel Gene
• Magnant Jerome Geoffrey

Classifications

• C04B41/009

  characterised by the material treated · CPC title

• F01D5/282

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• C04B41/87

  Ceramics · CPC title

• C04B41/85 Primary

  with inorganic materials · CPC title

• C04B41/52

  Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation} · CPC title