Preforms system for CMC blades

Patent metadata

Field	Value
Publication number	US-11428107-B2
Application number	US-201916429909-A
Country	US
Kind code	B2
Filing date	Jun 3, 2019
Priority date	Jun 3, 2019
Publication date	Aug 30, 2022
Grant date	Aug 30, 2022

Abstract

A bladed disk preform system is provided. Multiple sheets are formed or provided. Each of the sheets may include multiple ceramic fibers. Slots may be cut in each of the sheets before or after forming. The slots extend from an outer edge of the sheets inward toward a center of the sheets. The sheets are stacked on top of each other to form a bladed disk preform. The bladed disk preform is porous. The bladed disk preform may include a plurality of blade portions extending outward from a root portion. Each of the slots is positioned between adjacent blade portions.

First claim

What is claimed is:

1. A method comprising:
forming or providing a plurality of sheets, wherein each of the sheets includes a plurality of ceramic fibers;
cutting a plurality of slots in each of the sheets before each of the sheets is stacked on one or more of other of the plurality of sheets, the slots extending from an outer edge of the sheets inward toward a center of the sheets;
stacking and forming the sheets on top of each other to form a bladed disk preform, which is porous, wherein the bladed disk preform includes a plurality of blade portions extending outward from a root portion, and wherein each of the slots is positioned between adjacent blade portions.

2. The method of claim 1 , further comprising cutting a hole in each of the sheets, wherein the bladed disk preform is an annulus.

3. The method of claim 1 , wherein each of the sheets comprises a woven cloth, the woven cloth including a first set of ceramic fibers and a second set of ceramic fibers, wherein the first set of ceramic fibers is arranged transverse to the second set of ceramic fibers.

4. The method of claim 1 , wherein each of the sheets comprises a polar woven cloth, the polar woven cloth including a first set of ceramic fibers and a second set of ceramic fibers, wherein the first set of ceramic fibers are arranged around a center of the sheets to extend outward from the center, and wherein the second set of ceramic fibers is arranged in concentric arcs around the center of the sheets.

5. The method of claim 1 , wherein each of the sheets has a disk shape.

6. The method of claim 1 , further comprising cutting through the root portion along a plane extending through the root portion between adjacent blade portions to form a plurality of bladed disk preform segments.

7. The method of claim 6 , further comprising infiltrating the bladed disk preform segments; and forming a plurality of ceramic matrix composite (CMC) bladed disk segments, wherein each of the CMC bladed disk segments includes a blade and a root.

8. The method of claim 7 , wherein the root is fixable to a hub of a gas turbine engine.

9. The method of claim 6 , wherein each of the bladed disk preform segments includes at least two blade portions.

10. A method comprising:
forming or providing a plurality of sheets, wherein each of the sheets includes a plurality of ceramic fibers;
stacking and forming the sheets on top of each other to form a porous preform, the porous preform having an outer edge;
cutting a plurality of slots in the porous preform, the slots extending from an outer surface of the porous preform inward toward a center of the porous preform to define a bladed disk preform, the bladed disk preform including a plurality of blade portions and a root portion;
cutting through the root portion along a plane extending through the root portion between adjacent blades of the plurality of blade portions to form a plurality of bladed disk preform segments; and
after cutting through the root portion to form the plurality of bladed disk preform segments, infiltrating each of the plurality of bladed disk preform segments to form a plurality of ceramic matrix composite (CMC) bladed disk segments, wherein each of the plurality of CMC bladed disk segments includes a root and at least one blade extending away from the root.

11. The method of claim 10 , wherein each of the sheets has an annular shape.

12. The method of claim 11 , wherein the ceramic fibers include a first set and a second set of the ceramic fibers, wherein the first set of ceramic fibers comprises a different material than the second set of ceramic fibers.

13. The method of claim 12 , wherein the ceramic fibers include the first set and the second set of the ceramic fibers, wherein the first set of ceramic fibers comprises a different thickness than the second set of ceramic fibers.

14. The method of claim 13 , wherein each of the sheets comprises a woven cloth formed by the first set and the second set of the ceramic fibers.

15. The method of claim 14 , wherein the woven cloth comprises a polar woven cloth.

16. The method of claim 10 , wherein each of the CMC bladed disk segments is configured to be fixed to a hub of a gas turbine engine.

Assignees

• Rolls Royce Corp
• Rolls Royce High Temperature Composites Inc

Inventors

• Shi Jun
• Brown Steffan

Classifications

• F01D5/147

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• F01D5/34

  Rotor-blade aggregates of unitary construction {, e.g. formed of sheet laminae; (discs formed of sheet laminae F01D5/028; ceramic materials F01D5/284, composite materials F01D5/282)} · CPC title

• F05D2300/614

  Fibres or filaments · CPC title

• F01D5/282 Primary

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

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title