CMC blade track with integral abradable

Patent metadata

Field	Value
Publication number	US-11261750-B2
Application number	US-201815935721-A
Country	US
Kind code	B2
Filing date	Mar 26, 2018
Priority date	Mar 26, 2018
Publication date	Mar 1, 2022
Grant date	Mar 1, 2022

Abstract

A system and method for forming a ceramic matrix composite blade track is provided. The method may include stacking a plurality of first plies to form a first porous preform layer, the first plies including a plurality of first ceramic fibers. The method may further include stacking a plurality of second plies to form a second porous preform layer, the second plies including a plurality of second ceramic fibers. The method may further include combining the first porous preform layer and the second porous preform layer to form a unified porous preform. The method may further include forming a structural layer by infiltrating the first porous preform with a first ceramic matrix material, and forming an abradable layer by infiltrating the second porous preform with a second ceramic matrix material.

First claim

What is claimed is:

1. A method comprising:
forming a first porous preform layer comprising a plurality of first ceramic fibers, the first ceramic fibers woven together in a 3-D orientation and comprising a first oxide material;
coupling a plurality of second ceramic fibers to the first porous preform to form a second porous preform layer, the second ceramic fibers comprising a second oxide material different from the first oxide material, the first porous preform layer and the second porous preform layer together forming a unified porous preform, the second ceramic fibers woven together in the 3-D orientation;
forming a structural layer by infiltrating the first porous preform layer with a first ceramic matrix material; and
forming an abradable layer by infiltrating the second porous preform layer with a second ceramic matrix material different from the first ceramic material, wherein the structural layer and the abradable layer form a blade track.

2. The method of claim 1 further comprising infiltrating the second porous preform layer with a fugitive fiber.

3. The method of claim 2 further comprising removing the fugitive fiber from the abradable layer.

4. The method of claim 1 , wherein coupling the plurality of second ceramic fibers to the structural layer forms an interface between the structural layer and the abradable layer and a third ceramic fiber is positioned in the abradable layer and the structural layer and crosses the interface.

5. The method of claim 1 , further comprising forming the blade track into an annulus.

6. The method of claim 5 , wherein the annulus comprises a first portion and a second portion, the first portion comprising a first radius and the second portion comprising a second radius, a length of the first radius being nonequal to a length of the second radius.

7. The method of claim 1 , wherein the abradable layer has a lower local fiber density than the structural layer.

8. The method of claim 1 , wherein the abradable layer comprises a first region and a second region, the first region having a lower local fiber density than the second region.

9. The method of claim 1 , wherein the first ceramic fibers comprise alumina or aluminosilicate fibers and wherein the second ceramic fibers comprise at least one of silicate glass, alumina, or aluminosilicate.

10. A method comprising:
stacking a plurality of first plies to form a first porous preform layer, the first plies comprising a plurality of first ceramic fibers;
stacking a plurality of second plies to form a second porous preform layer, the second plies comprising a plurality of second ceramic fibers;
combining the first porous preform layer and the second porous preform layer to form a unified porous preform;
forming a structural layer by infiltrating the first porous preform with a first ceramic matrix material;
forming an abradable layer by infiltrating the second porous preform with a second ceramic matrix material, wherein the structural layer and the abradable layer form a first blade track; and
forming a second blade track by coupling the stacked abradable layer to the stacked structural layer, and coupling the first blade track to the second blade track.

11. The method of claim 10 , wherein at least one of the first ceramic fibers or the second ceramic fibers comprise a plurality of discontinuous fibers; and
applying the first ceramic matrix material to the discontinuous fibers or applying the second ceramic matrix material to the discontinuous fibers.

12. The method of claim 11 , further comprising chopping a source fiber to obtain the discontinuous fibers, and wherein applying the first ceramic matrix material to the discontinuous fibers or applying the second ceramic matrix material to the discontinuous fibers occurs simultaneously to chopping the source fiber.

13. The method of claim 10 , further comprising removing a fugitive fiber from the abradable layer.

14. The method of claim 10 , wherein at least one of the first ceramic fibers or the second ceramic fibers comprise discontinuous fibers.

15. The method of claim 10 , further comprising forming the blade track into an annulus.

Assignees

• Rolls Royce Nam Tech Inc
• Rolls Royce Corp

Inventors

• Landwehr Sean
• Freeman Ted
• Sippel Aaron

Classifications

• C04B2237/38

  Fiber or whisker reinforced · CPC title

• C04B2235/5228

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

• F01D11/122 Primary

  with erodable or abradable material (blades having cutting or grinding tips F01D5/20) · CPC title

• C04B35/80

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

• C04B35/82

  Asbestos; Glass; Fused silica · CPC title