Additively manufactured composite components

Patent metadata

Field	Value
Publication number	US-11559918-B2
Application number	US-201816156630-A
Country	US
Kind code	B2
Filing date	Oct 10, 2018
Priority date	Oct 10, 2018
Publication date	Jan 24, 2023
Grant date	Jan 24, 2023

Abstract

An example technique includes extruding, by a tow deposition device, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material on a major surface of a substrate. Each respective impregnated tow includes at least one ceramic fiber and a curable resin coating the at least one ceramic fiber. The example technique includes curing the curable resin to form a cured composite component. An example system includes a tow deposition device, an energy source, and a computing device. The computing device is configured to control the tow deposition device to extrude, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material, and is configured to control the energy source to cure the curable resin to form a cured composite component.

First claim

What is claimed is:

1. A method comprising:
continuously coating a tow with an interface coating using a vapor phase process to form an interface coated tow, wherein the tow comprises at least one ceramic fiber;
continuously coating the interface coating of the interface coated tow with a curable resin to form an impregnated tow, wherein the curable resin is chosen from a thermoplastic polymeric material, a precursor curable to form a thermoplastic polymeric material, wherein the thermoplastic polymeric material is chosen from polyvinyl alcohol, polyolefins, polystyrene, acrylonitrile butadiene styrene, polylactic acid, thermoplastic polyurethane, aliphatic polyamides, and combinations thereof, or a high-char yield resin, wherein the high-char yield resin is chosen from furfuryl alcohol, a polymer derived from polymerizing furfuryl alcohol, or a phenolic material;
extruding, by a tow deposition device, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a first layer of material on a major surface of a substrate;
curing the curable resin to form a cured composite component; and
melt infiltrating the cured composite component to form a ceramic matrix composite (CMC).

2. The method of claim 1 , further comprising, prior to extruding the respective impregnated tows continuously advancing the impregnated tow into the tow deposition device, wherein extruding respective impregnated tows comprises positioning the impregnated tow at a desired location in the first layer of material and cutting the impregnated tow to define a respective impregnated tow of the plurality of impregnated tows.

3. The method of claim 1 , wherein curing the curable resin comprises thermally curing or photocuring the curable resin.

4. The method of claim 1 , wherein the respective impregnated tows are aligned along a first direction, further comprising:
extruding, by the tow deposition device, on a tow-by-tow basis, respective impregnated tows of the plurality of respective impregnated tows to form a second layer of material on a major surface of the first layer of material, wherein the respective impregnated tows in the second layer of material are aligned along a second direction different from the first direction.

5. The method of claim 4 , wherein the second direction is perpendicular to the first direction along a plane between the first layer and the second layer.

6. The method of claim 4 , wherein each respective impregnated tow of the first layer of material has substantially the same transverse thickness as each respective impregnated tow of the second layer of material.

7. The method of claim 4 , wherein the respective impregnated tows of the first layer of material have a transverse thickness different from the respective impregnated tows of the second layer of material.

8. The method of claim 1 , wherein extruding the respective impregnated tows comprises controlling, by a computing device, based on a model of the cured composite component, the tow deposition device to extrude the respective impregnated tows of the plurality of impregnated tows.

9. The method of claim 8 , wherein the tow deposition device is a first tow deposition device configured to extrude respective impregnated tows in a first layer, the method further comprising controlling, by the computing device, based on the model, a second tow deposition device to extrude respective impregnated tows in a second layer on the first layer.

10. The method of claim 1 , wherein the interface coating defines a compliant layer between the at least one ceramic fiber and the curable resin.

11. The method of claim 1 , wherein the interface coating comprises at least one of carbon, aluminum nitride, boron nitride, silicon nitride, silicon carbide, boron carbide, a metal boride, a transition metal silicide, a transition metal oxide, a transition metal silicate, or a rare earth metal silicate.

12. The method of claim 1 , wherein the interface coating at least partially extends into an interior of the tow.

13. A method comprising:
continuously coating a tow with an interface coating using a vapor phase process to form an interface coated tow, wherein the tow comprises at least one ceramic fiber;
continuously coating the interface coating of the interface coated tow with a curable resin to form an impregnated tow, wherein the curable resin is chosen from a thermoplastic polymeric material, a precursor curable to form a thermoplastic polymeric material, wherein the thermoplastic polymeric material is chosen from polyvinyl alcohol, polyolefins, polystyrene, acrylonitrile butadiene styrene, polylactic acid, thermoplastic polyurethane, aliphatic polyamides, and combinations thereof, or a high-char yield resin, wherein the high-char yield resin is chosen from furfuryl alcohol, a polymer derived from polymerizing furfuryl alcohol, or a phenolic material;
extruding, by a tow deposition device, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a plurality of layers of material;
laying up the plurality of layers of the material on a major surface of a substrate to form a laid-up component;
curing the curable resin to form a cured composite component; and
melt infiltrating the cured composite component to form a ceramic matrix composite (CMC).

14. The method of claim 13 , wherein curing the curable resin comprises thermally curing the curable resin or photocuring the curable resin.

15. The method of claim 13 , wherein the extruding comprises controlling, by a computing device, based on a model of the cured composite component, at least one tow deposition device to extrude the respective impregnated tows of the plurality of impregnated tows.

Assignees

• Rolls Royce Corp
• Rolls Royce High Temperature Composites Inc

Inventors

• Shim Sungbo
• Nation Cory
• Abbott Michael G

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B28B1/001 Primary

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B28B17/0081

  Process control · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title