Methods and assemblies for forming features in composite components

Patent metadata

Field	Value
Publication number	US-10502074-B2
Application number	US-201715481611-A
Country	US
Kind code	B2
Filing date	Apr 7, 2017
Priority date	Apr 7, 2017
Publication date	Dec 10, 2019
Grant date	Dec 10, 2019

Abstract

Various methods and assemblies are provided for producing composite components having formed in features. For example, a method may comprise depositing a composite material on a base tool; deploying a feature forming tool to press the composite material into one or more recesses; and processing the composite material with the feature forming tool pressing the composite material into the one or more recesses. The processed composite material forms a green state composite component. The feature forming tool comprises one or more forming members, supported by a frame, for forming one or more features of the composite component. The method also may include sealing a bag around the composite material before deploying a feature forming tool and removing the feature forming tool and the bag after processing the composite material.

First claim

What is claimed is:

1. A method for forming features in a composite component, comprising:
depositing a composite material on a base tool;
deploying a feature forming tool to press the composite material into one or more recesses; and
processing the composite material with the feature forming tool pressing the composite material into the one or more recesses, the processed composite material forming a green state composite component,
wherein the feature forming tool comprises one or more forming members for forming one or more features of the composite component, the forming members supported by a frame,
wherein each forming member comprises:
a shank extending through the frame, the shank having a first end opposite a second end, the second end located between the frame and the composite material when the feature forming tool is positioned to be deployed, and
a feature forming head at the second end of the shank, and

wherein a biasing member is positioned between the frame and the feature forming head to urge the feature forming head toward the composite material to press the composite material into the one or more recesses.

2. The method of claim 1 , further comprising, after depositing the composite material on the base tool but prior to deploying the feature forming tool:
sealing a bag around the composite material.

3. The method of claim 1 , further comprising, after processing the composite material with the feature forming tool pressing the composite material into the one or more recesses:
removing the feature forming tool from the green state composite component; and
finish processing the green state composite component to produce the composite component.

4. The method of claim 1 , wherein deploying the feature forming tool comprises aligning the frame with an alignment feature of the base tool, then lowering the forming members such that the composite material is guided into the one or more recesses.

5. The method of claim 1 , wherein the base tool comprises one recess corresponding to each forming member, each recess shaped complementary to the one or more forming members.

6. The method of claim 1 , wherein deploying the feature forming tool comprises aligning the frame with an alignment feature of the base tool, then lowering the one or more forming members toward the composite material until the composite material is pressed into the one or more recesses, and wherein the first end of the shank extends beyond the frame, and wherein a wedge is positioned between the frame and a collar on the first end of the shank of each forming member to hold the feature forming head away from the composite material until the frame is aligned with the alignment feature of the base tool.

7. The method of claim 6 , wherein each wedge is positioned within a gap, and wherein the gap is sized to limit a force applied to the composite material by the forming member.

8. The method of claim 1 , wherein the one or more features include a countersink.

9. The method of claim 1 , wherein the one or more features include a counterbore.

10. A method for forming features in a composite component, comprising:
depositing a composite material on a base tool;
sealing a bag around the composite material;
deploying a feature forming tool to press the composite material into one or more recesses, the feature forming tool comprising one or more forming members for forming one or more features of the composite component, the forming members supported by a frame;
processing the composite material with the feature forming tool pressing the composite material into the one or more recesses, the processed composite material forming a green state composite component;
removing the feature forming tool and the bag from the green state composite component;
firing the green state composite component to produce a fired composite component; and
densifying the fired composite component to produce the composite component,
wherein the green state composite component comprises the one or more features formed by the feature forming tool.

11. The method of claim 10 , wherein the one or more features include a countersink.

12. The method of claim 10 , wherein the one or more features include a counterbore.

13. The method of claim 10 , wherein deploying the feature forming tool comprises aligning the frame with an alignment feature of the base tool, then lowering the forming members toward the composite material until the composite material is pressed into the one or more recesses.

14. The method of claim 10 , wherein the base tool comprises one recess corresponding to each forming member, each recess shaped complementary to the one or more forming members.

15. The method of claim 10 , wherein each forming member comprises:
a shank extending through the frame, the shank having a first end opposite a second end, the second end located between the frame and the composite material when the feature forming tool is positioned to be brought into contact with the composite material, and
a feature forming head at the second end of the shank, and
wherein a biasing member is positioned between the frame and the feature forming head to urge the feature forming head toward the composite material to press the composite material into the one or more recesses.

16. The method of claim 15 , wherein deploying the feature forming tool comprises aligning the frame with an alignment feature of the base tool, then lowering the one or more forming members toward the composite material until the composite material is pressed into the one or more recesses, and wherein the first end of the shank extends beyond the frame, and wherein a wedge is positioned between the frame and a collar on the first end of the shank of each forming member to hold the feature forming head away from the composite material until the frame is aligned with the alignment feature of the base tool.

17. The method of claim 10 , wherein the composite material is a plurality of composite plies formed from a ceramic matrix composite material.

18. A method for forming features in a composite component, comprising:
depositing a composite material on a base tool;
sealing a bag around the composite material;
deploying a feature forming tool to press the composite material into one or more recesses, the feature forming tool comprising one or more forming members for forming one or more features of the composite component, the forming members supported by a frame, each forming member comprising:
a shank extending through the frame, the shank having a first end opposite a second end, the second end located between the frame and the composite material when the feature forming tool is positioned to be brought into contact with the composite material, and
a feature forming head at the second end of the shank;

processing the composite material with the feature forming tool pressing the composite material into the one or more recesses, the processed composite material forming a green state composite component; and
removing the feature forming tool and the bag from the green state composite component,
wherein the green state composite component comprises the one or more features formed by the feature forming tool, and
wherein a biasing member is positioned between the frame and the feature forming head to urge the feature forming head toward the composite material to press the composite material into the one or more recesses.

19. The method of claim 18 , wherein deploying the feature forming tool comprises aligning

Assignees

• Gen Electric

Inventors

• Corsmeier Donald Michael

Classifications

• B29C70/345 Primary

  using matched moulds · CPC title

• C04B35/622

  Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products · CPC title

• B29C70/342 Primary

  using isostatic pressure · CPC title

• F05D2300/614

  Fibres or filaments · CPC title

• F01D5/282 Primary

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