Method to additively manufacture a fiber-reinforced ceramic matrix composite

Patent metadata

Field	Value
Publication number	US-11155502-B2
Application number	US-201816472866-A
Country	US
Kind code	B2
Filing date	Jan 2, 2018
Priority date	Jan 25, 2017
Publication date	Oct 26, 2021
Grant date	Oct 26, 2021

Abstract

A method of additively manufacturing a ceramic matrix composite material includes providing a ceramic fiber and a powdery base material for a ceramic matrix composite and layer-by-layer building up the ceramic matrix material for the ceramic matrix composite by irradiating of a powder bed formed by the base material with an energy beam according to a predetermined geometry, wherein the base material is melted, solidified and adhesively joined to the ceramic fiber in that parameters of the energy beam are locally chosen such that in the contact region of the ceramic fiber and the powder bed, the ceramic fiber is only partly melted.

First claim

The invention claimed is:

1. A method of additively manufacturing a ceramic matrix composite comprising:
providing a ceramic fiber and a powdery base material for the ceramic matrix composite,
layer-by-layer building up ceramic matrix material for the ceramic matrix composite by irradiating a powder bed formed by the base material with an energy beam according to a predetermined geometry, wherein the base material is melted, solidified and adhesively joined to the ceramic fiber within each layer of the ceramic matrix composite in that parameters of the energy beam are locally chosen such that in a contact region of the ceramic fiber and the powder bed within each layer of the ceramic matrix composite, the ceramic fiber is only partly melted.

2. The method according to claim 1 ,
wherein the fiber is pre-positioned in a build space for the additive manufacture prior to the irradiation.

3. The method according to claim 1 ,
wherein the fiber is placed in the powder bed during the additive manufacture by a movable apparatus.

4. The method according to claim 1 ,
wherein a thickness of the fiber amounts to more than half of a layer thickness of the base material for the layer-by-layer build-up.

5. The method according to claim 1 ,
wherein a diameter of particles of the base material is five to ten times smaller than a thickness of the fiber.

6. The method according to claim 1 ,
wherein a mode of the irradiation with the energy beam at a transition from a powder bed region, into the contact region is changed such that the material of the fiber is only partly melted.

7. The method according to claim 6 ,
wherein, in the powder bed region, the irradiation with the energy beam is carried out in a continuous wave mode and, in the contact region, the irradiation with the energy beam is carried out in a pulsed mode,
wherein at least one of the parameters of the energy beam chosen from power, pulse duration, repetition rate and pulse shape are adapted.

8. The method according to claim 6 ,
wherein a power or power density of the energy beam is reduced at the transition from the powder bed region to the contact region.

9. The method according to claim 1 ,
wherein the fiber has a filament shape and a diameter of the fiber is increased prior to the layer-by-layer buildup by a coating, and
wherein material of the coating is melted during the irradiation.

10. The method according to claim 9 ,
wherein the fiber has the filament shape and the diameter of the fiber is increased prior to the layer-by-layer buildup by oxidic coating, and
wherein the respective coating material is melted during the irradiation.

11. The method according to claim 1 ,
wherein the fiber and the base material are made of or comprise similar ceramic materials.

12. The method according to claim 11 ,
wherein the similar ceramic materials comprise the material systems C/C, SiC/SiC, Al2O3/Al2O3, ZrO2/ZrO2 or mullite/mullite.

13. The method according to claim 1 ,
wherein the fiber and the base material are made of or comprise dissimilar ceramic materials.

14. The method according to claim 13 ,
wherein the dissimilar ceramic materials comprise the material systems C/SiC, or Al2O3/ZrO2.

15. The method according to claim 1 ,
wherein the powder bed is preheated to temperatures of above 1500° C. for the prevention of rupture and/or stresses, or is preheated to temperatures of above 1500° C. by a laser, or a CO2- or Nd:YAG-laser, an electron beam or inductive heating.

16. The method according to claim 1 ,
wherein the ceramic matrix composite is not structurally post-processed, or postprocessed by hot isostatic pressing and/or post-infiltration, after the layer-by-layer build-up.

Assignees

• Siemens Ag
• Siemens Energy Global Gmbh & Co Kg

Inventors

• Brandt Milan
• Dietrich Jens
• Kelbassa Ingomar

Classifications

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• C04B35/657

  for manufacturing refractories (C04B35/05, C04B35/107, C04B35/484 take precedence) · CPC title

• C04B2235/428

  Silicon · CPC title

• C04B2235/616

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

• C04B2235/5228

  Silica and alumina, including aluminosilicates, e.g. mullite · CPC title