Method for producing a hollow part made of a ceramic matrix composite material

Patent metadata

Field	Value
Publication number	US-11608299-B2
Application number	US-201816652481-A
Country	US
Kind code	B2
Filing date	Sep 25, 2018
Priority date	Oct 2, 2017
Publication date	Mar 21, 2023
Grant date	Mar 21, 2023

Abstract

A method for producing a hollow part made of a ceramic matrix composite material. The method includes shaping a hollow fibrous preform. A core of oxidizable material is housed or inserted into the preform. The method also includes consolidating the preform and extracting the core by oxidising the core.

First claim

The invention claimed is:

1. A method for producing a hollow part made of a ceramic matrix composite material comprising the steps of:
shaping a hollow fibrous preform, a core made of an oxidizable material being housed or inserted into the preform;
consolidating said preform; and
extracting the core by oxidizing said core;
wherein the step of extracting the core by oxidizing said core comprises the following sub-steps:
heating the preform in which the core is inserted, in a furnace under an oxidizing atmosphere in a first heating cycle lasting between 20 hours and 30 hours;
mechanically removing part of the oxidized core by scraping;
heating the preform in the furnace under an oxidizing atmosphere in a second heating cycle lasting between 10 hours and 15 hours; and
mechanically removing a rest of the oxidized core by scraping.

2. The method according to claim 1 , wherein said heating is carried out in the presence of a catalyst.

3. The method according to claim 2 , wherein the catalyst comprises potassium acetate.

4. The method according to claim 1 , wherein said heating is carried out at a temperature ranging from 400° C. to 800° C.

5. The method according to claim 1 , wherein the oxidizable core is made of carbon, graphite or other material derived from carbon.

6. The method according to claim 1 , wherein the hollow fibrous preform is made by draping or assembling fibrous textures around the core, or by weaving a preform having a hollow area for insertion of the core.

7. The method according to claim 1 , wherein said consolidation of the preform comprises the sub-steps of:
creating at least one interphase on the fibres of the fibrous preform by chemical vapour infiltration; and
creating at least one ceramic matrix layer on the interphase by chemical vapour infiltration.

8. The method according to claim 7 , wherein the at least one interphase comprises boron nitride.

9. The method according to claim 7 , wherein the at least one ceramic matrix layer comprises silicon carbide.

10. The method according to claim 1 , wherein the step of extracting the core by oxidation is followed by a step of densification of the preform comprising:
the introduction of a metal powder into the preform; and
the infiltration of molten metal into the preform.

11. The method according to claim 10 , wherein the metal power comprises a silicon powder.

12. The method according to claim 10 , wherein the molten metal comprises a molten silicon.

13. The method according to claim 1 , wherein the step of extracting the core by oxidation is followed by the steps of:
machining the part; and
covering the outer surface of the part with a coating forming a thermal or environmental barrier.

Assignees

• Safran Ceram

Inventors

• Gimat Matthieu Arnaud
• Dupont Rémy
• Carlin Maxime François Roger
• Philippe Eric
• Lacombe Benjamin

Classifications

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title

• C04B2235/612

  Machining · CPC title

• C04B2235/422

  Carbon · CPC title

• C04B35/62884

  by gas phase techniques · CPC title

• C04B35/52

  based on carbon, e.g. graphite · CPC title