Ceramic matrix composite components reinforced for managing multi-axial stresses and methods for fabricating the same

Patent metadata

Field	Value
Publication number	US-10480108-B2
Application number	US-201715446582-A
Country	US
Kind code	B2
Filing date	Mar 1, 2017
Priority date	Mar 1, 2017
Publication date	Nov 19, 2019
Grant date	Nov 19, 2019

Abstract

Ceramic matrix composite components and methods for fabricating ceramic matrix composite components are provided. In one example, a ceramic matrix composite component includes a ceramic matrix composite body. The ceramic matrix composite body includes a layer-to-layer weave of ceramic fibers and a layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers disposed adjacent to the layer-to-layer weave. When stressed, the ceramic matrix composite body forms a relatively high through-thickness stress region and a relatively high in-plane bending stress region. The layer-to-layer weave is disposed through the relatively high through-thickness stress region and the layer of 1D/2D fabric is disposed through the relatively high in-plane bending stress region.

First claim

What is claimed is:

1. A ceramic matrix composite component, the ceramic matrix composite component comprising:
a ceramic matrix composite body comprising a layer-to-layer weave of ceramic fibers and at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers disposed adjacent to the layer-to-layer weave, the ceramic matrix composite body including a relatively high through-thickness stress region and a relatively high in-plane bending stress region, the layer-to-layer weave is disposed through the relatively high through-thickness stress region and the at least one layer of 1D/2D fabric is disposed through the relatively high in-plane bending stress region,
wherein the ceramic matrix composite body includes an inside-facing outer surface section and an interior mid-section surrounding the inside-facing outer surface section, and wherein the at least one layer of 1D/2D fabric is disposed in the inside-facing outer surface section and the layer-to-layer weave is disposed in the interior mid-section.

2. The ceramic matrix composite component of claim 1 , wherein the layer-to-layer weave comprises a 2.5-dimensional weave of ceramic fibers.

3. The ceramic matrix composite component of claim 1 , wherein the layer-to-layer weave comprises a 3-dimensional weave of ceramic fibers.

4. The ceramic matrix composite component of claim 1 , wherein the ceramic matrix composite body is a component of a gas turbine engine.

5. The ceramic matrix composite component of claim 4 , wherein the ceramic matrix composite body is a seal segment of the gas turbine engine, wherein the inside-facing outer surface section is substantially concave.

6. The ceramic matrix composite component of claim 4 , wherein the ceramic matrix composite body is a vane or blade of the gas turbine engine.

7. The ceramic matrix composite component of claim 6 , wherein the vane or blade of the gas turbine engine is an internally cooled vane or blade, wherein the inside-facing outer surface section surrounds a cooling channel.

8. The ceramic matrix composite component of claim 1 , wherein the relatively high in-plane bending stress region includes a relatively high in-plane tensile stress region and a relatively high in-plane compression stress region, wherein the relatively high through-thickness stress region is disposed between the relatively high in-plane tensile stress region and the relatively high in-plane compression stress region, and wherein the at least one layer of 1D/2D fabric is disposed through the relatively high in-plane tensile stress region.

9. The ceramic matrix composite component of claim 8 , wherein the at least one layer of 1D/2D fabric is disposed through the relatively high in-plane compression stress region.

10. The ceramic matrix composite component of claim 8 , wherein the layer-to-layer weave is disposed through the relatively high in-plane compression stress region.

11. A method for fabricating a ceramic matrix composite component, the method comprising:
forming a porous ceramic preform into a ceramic matrix composite body, wherein the porous ceramic preform comprises a layer-to-layer weave of ceramic fibers and at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers by:
arranging, the at least one layer of 1D/2D fabric on an inside facing surface of the ceramic matrix composite body in a relatively high in-plane bending stress region of the ceramic matrix composite body; and
arranging the layer-to-layer weave in an interior mid-section surrounding the inside-facing outer surface section in a relatively high through-thickness stress region of the ceramic matrix composite body.

12. The method of claim 11 , wherein forming the ceramic matrix composite body comprises:
infiltrating a molten metal or alloy into the porous ceramic preform; and
solidifying the molten metal or alloy to form the ceramic matrix composite body.

13. The method of claim 11 , further comprising providing the porous ceramic preform comprising forming a layup that comprises the layer-to-layer weave and the at least one layer of 1D/2D fabric disposed adjacent to the layer-to-layer weave.

14. The method of claim 13 , wherein forming the layup comprises arranging the layer-to-layer weave comprising a 2.5-dimensional weave of ceramic fibers in the layup.

15. The method of claim 13 , wherein forming the layup comprises arranging the layer-to-layer weave comprising a 3-dimensional weave of ceramic fibers in the layup.

16. A ceramic matrix composite component, the ceramic matrix composite component comprising:
a ceramic matrix composite body comprising a layer-to-layer weave of ceramic fibers and at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers disposed adjacent to the layer-to-layer weave,
the ceramic matrix composite body including a relatively high in-plane bending stress region, the relatively high in-plane bending stress region including a relatively high in-plane tensile stress region, a relatively high in-plane compression stress region,
wherein the at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers is disposed in the relatively high in-plane tensile stress region and the layer-to-layer weave is disposed in the relatively high in-plane compression stress region.

17. The ceramic matrix composite component of claim 16 , wherein a relatively high through-thickness stress region disposed between the relatively high in-plane tensile stress region and the relatively high in-plane compression stress region.

18. The ceramic matrix composite component of claim 17 , wherein the ceramic matrix composite body has an outer surface section and an interior mid-section that is disposed adjacent to the outer surface section, wherein the at least one layer of 1D/2D fabric is disposed in the outer surface section of the ceramic matrix composite body, and wherein the layer-to-layer weave is disposed in the interior mid-section of the ceramic matrix composite body.

19. The ceramic matrix composite component of claim 16 , wherein ceramic matrix composite body is a non-internally cooled vane or blade of a gas turbine engine having an outer surface section that surrounds a substantially solid interior mid-section, and wherein the at least one layer of 1D/2D fabric is disposed in the outer surface section and the layer-to-layer weave is disposed in the substantially solid interior mid-section of the non-internally cooled vane or blade.

20. The ceramic matrix composite component of claim 16 , wherein the ceramic matrix composite body is an annular ceramic matrix composite combustor of a gas turbine engine, wherein the annular ceramic matrix composite combustor has an interior mid-section surrounding a cooling channel and an outside-facing outer surface section that surrounds the interior mid-section, and wherein the at least one layer of 1D/2D fabric is disposed in the outside-facing outer surface section and the layer-to-layer weave is disposed in the interior mid-section of the annular ceramic matrix composite combustor.

Assignees

• Rolls Royce Corp

Inventors

• Shi Jun

Classifications

• F01D5/187

  Convection cooling · CPC title

• B22F5/009

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title

• C04B35/62227

  obtaining fibres · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B2235/5252

  having a specific pre-form · CPC title