Tooling inserts for ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-11623366-B2
Application number	US-201816191305-A
Country	US
Kind code	B2
Filing date	Nov 14, 2018
Priority date	Dec 15, 2017
Publication date	Apr 11, 2023
Grant date	Apr 11, 2023

Abstract

The disclosure describes a system that includes a controller configured to receive a representation of a three-dimensional geometry of a preform, determine a set of dimensions of the preform from the representation of the preform, and determine dimensions of at least one insert for a fixed tooling based on a dimensional tolerance of the preform, the set of dimensions of the preform, and dimensions of the fixed tooling.

First claim

What is claimed is:

1. A method comprising:
causing a controller to:
determine a set of dimensions of a preform from a representation of a three-dimensional geometry of the preform; and
determine dimensions of at least one insert for a fixed tooling based on a dimensional tolerance of a greenbody preform formed from the preform, the set of dimensions of the preform, and dimensions of the fixed tooling, wherein the fixed tooling defines a tooling volume between a bulk exterior surface of the preform and an interior surface of the fixed tooling;

causing an insert fabrication unit to manufacture the at least one insert based on the determined dimensions;
positioning the at least one insert in the fixed tooling;
positioning the preform within the fixed tooling to contact the at least one insert;
causing a slurry infiltration system to infiltrate the preform with a slurry to form an infiltrated preform, wherein infiltrating the preform with the slurry includes adding the slurry to the tooling volume; and
causing the slurry infiltration system to dry the infiltrated preform to form the greenbody preform, wherein a set of dimensions of the greenbody preform is different from the set of dimensions of the preform.

2. The method of claim 1 , wherein the at least one insert comprises at least one adaptive standoff configured to contact more than one surface of the preform.

3. The method of claim 1 , wherein the at least one insert comprises at least one fixed shim and the fixed tooling comprises structures configured to house the at least one fixed shim.

4. The method of claim 1 , wherein the fixed tooling comprises a textured interior surface.

5. The method of claim 1 ,
wherein the slurry comprises a ceramic powder
wherein the greenbody preform includes a matrix and a surface coating each comprising the ceramic powder.

6. The method of claim 4 , wherein the surface coating of the greenbody preform includes the textured interior surface of the fixed tooling.

7. A method comprising:
causing a controller to:
determine a set of dimensions of a preform from a representation of a three-dimensional geometry of the preform;
determine dimensions of at least one insert for a fixed tooling based on a dimensional tolerance of a greenbody preform formed from the preform, the set of dimensions of the preform, and dimensions of the fixed tooling, wherein the fixed tooling defines a tooling volume between a bulk exterior surface of the preform and an interior surface of the fixed tooling; and
output an indication of a placement parameter of the at least one insert based on the determined dimensions of the at least one insert;

positioning the at least one insert in the fixed tooling;
positioning the preform within the fixed tooling to contact the at least one insert;
causing a slurry infiltration system to infiltrate the preform with a slurry to form an infiltrated preform, wherein infiltrating the preform with the slurry includes adding the slurry to the tooling volume; and
causing the slurry infiltration system to dry the infiltrated preform to form a greenbody preform, wherein a set of dimensions of the greenbody preform is different from the set of dimensions of the preform.

8. The method of claim 7 , wherein the at least one insert comprises at least one fixed shim, the fixed tooling comprises at least one structure configured to house the at least one fixed shim, and the placement parameter comprises a type of the at least one insert that includes the determined dimensions.

9. The method of claim 7 , wherein the at least one insert comprises at least one adaptive shim, the fixed tooling comprises at least one channel configured to house the at least one adaptive shim, the placement parameter comprises a placement distance of the at least one adaptive shim, and the at least one adaptive shim is positioned into the fixed tooling based on the placement distance.

10. The method of claim 7 , wherein the fixed tooling comprises a textured interior surface.

11. A system, comprising:
a controller configured to:
receive a representation of a three-dimensional geometry of a preform;
determine a set of dimensions of the preform from the representation of the preform; and
determine dimensions of at least one insert for a fixed tooling based on a dimensional tolerance of a greenbody preform formed from the preform, the set of dimensions of the preform, and dimensions of the fixed tooling, wherein the fixed tooling defines a tooling volume between a bulk exterior surface of the preform and an interior surface of the fixed tooling; and

a slurry infiltration system configured to:
infiltrate the preform with a slurry to form an infiltrated preform, wherein infiltrating the preform with the slurry includes adding the slurry to the tooling volume, and
dry the infiltrated preform to form the greenbody preform, wherein a set of dimensions of the greenbody preform is different from the set of dimensions of the preform.

12. The system of claim 11 , wherein the system further comprises an insert fabrication unit, and wherein the controller is further configured to control the insert fabrication unit to manufacture the at least one insert based on the determined dimensions.

13. The system of claim 11 , wherein the controller is further configured to output an indication of a placement parameter of the at least one insert based on the determined dimensions of the at least one insert.

14. The system of claim 11 , further comprising the fixed tooling configured to:
house the at least one insert in the fixed tooling based on the dimensions of the at least one insert; and
house the preform within the fixed tooling to contact the at least one insert.

15. The system of claim 11 , wherein the at least one insert comprises at least one fixed shim and the fixed tooling comprises structures configured to house the at least one fixed shim.

16. The system of claim 11 , wherein the at least one insert comprises at least one adaptive shim and the fixed tooling comprises at least one channel configured to house the at least one adaptive shim.

17. The system of claim 11 , wherein the at least one insert comprises at least one adaptive standoff configured to contact more than one surface of the preform.

18. The system of claim 14 , wherein the fixed tooling comprises a textured interior surface.

19. The system of claim 12 , wherein the insert fabrication unit comprises a three-dimensional printer.

Assignees

• Rolls Royce Corp

Inventors

• Ritchey Andrew James

Classifications

• C04B35/6264

  Mixing media, e.g. organic solvents · CPC title

• B28B23/0006 Primary

  the reinforcement consisting of aligned, non-metal reinforcing elements · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C04B35/6263

  characterised by their solids loadings, i.e. the percentage of solids · CPC title

• C04B2235/606

  Drying · CPC title