Ceramic matrix composite manufacturing

Patent metadata

Field	Value
Publication number	US-10712005-B2
Application number	US-201715650400-A
Country	US
Kind code	B2
Filing date	Jul 14, 2017
Priority date	Jul 14, 2017
Publication date	Jul 14, 2020
Grant date	Jul 14, 2020

Abstract

A method of manufacturing a ceramic matrix composite component may include introducing a gaseous precursor into an inlet portion of a chamber that houses a porous preform and introducing a gaseous mitigation agent into an outlet portion of the chamber that is downstream of the inlet portion of the chamber. The gaseous precursor may include methyltrichlorosilane (MTS) and the gaseous mitigation agent may include hydrogen gas. The introduction of the gaseous precursor may result in densification of the porous preform(s) and the introduction of the gaseous mitigation agent may shift the reaction equilibrium to disfavor the formation of harmful and/or pyrophoric byproduct deposits, which can accumulate in an exhaust conduit 340 of the system.

First claim

What is claimed is:

1. A method of manufacturing a ceramic matrix composite component, the method comprising:
introducing a gaseous precursor into an inlet portion of a chamber such that the gaseous precursor infiltrates a porous preform housed in the inlet portion of the chamber to densify the porous preform; and
introducing a gaseous mitigation agent into an outlet portion of the chamber that is downstream of the inlet portion of the chamber such that the gaseous mitigation agent flows through a gas mixing substrate loaded within a gas mixing space defined by the outlet portion of the chamber;
wherein the porous preform is only disposed in the inlet portion of the chamber;
wherein the gas mixing substrate is only disposed in the outlet portion of the chamber; and
wherein introducing the gaseous precursor and introducing the gaseous mitigation agent are performed simultaneously, with the gaseous mitigation agent only flowing through the outlet portion of the chamber and not flowing through the inlet portion of the chamber.

2. The method of claim 1 , wherein the gaseous precursor comprises methyltrichlorosilane (MTS).

3. The method of claim 2 , wherein the gaseous mitigation agent comprises hydrogen gas.

4. The method of claim 3 , wherein introducing the gaseous precursor is performed at a first molar flow rate and introducing the gaseous mitigation agent is performed at a second molar flow rate that is greater than the first molar flow rate.

5. The method of claim 4 , wherein the second molar flow rate is between 50% and 300% higher than the first molar flow rate.

6. The method of claim 4 , wherein the second molar flow rate is between 100% and 200% higher than the first molar flow rate.

7. The method of claim 3 , wherein the gaseous precursor also comprises hydrogen gas.

8. The method of claim 7 , wherein the methyltrichlorosilane comprises about 5% of the gaseous precursor.

9. The method of claim 1 , wherein the gaseous mitigation agent comprises introducing the gaseous mitigation agent into an upstream side of the outlet portion of the chamber.

Assignees

• Goodrich Corp

Inventors

• She Ying
• Menon Naveen G
• Dardas Zissis A
• Filburn Thomas P

Classifications

• F23R3/007 Primary

  constructed mainly of ceramic components · CPC title

• C04B35/80 Primary

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• C04B35/62828

  Non-oxide ceramics · CPC title

• C04B2235/46

  Gases other than oxygen used as reactant, e.g. nitrogen used to make a nitride phase · CPC title

• C23C16/325

  Silicon carbide · CPC title