CMC combustor shell with integral chutes

Patent metadata

Field	Value
Publication number	US-11796174-B2
Application number	US-201916518575-A
Country	US
Kind code	B2
Filing date	Jul 22, 2019
Priority date	Aug 25, 2015
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

A combustion assembly for a gas turbine engine may be provided. The combustion assembly may include a ceramic matrix composite combustor shell, which may include a chamber defined by a wall of the ceramic matrix composite combustor shell, and the ceramic matrix composite combustor shell may include a ceramic matrix composite chute integral with the ceramic matrix composite combustor shell. The ceramic matrix composite chute may extend towards a midline of the chamber. A method for fabricating a ceramic matrix composite chute may be provided. At least one chute may be woven in three dimensions into a ceramic preform. A layup tool may be inserted into the chute. The chute may be enlarged with the layup tool. The ceramic preform may be formed into a ceramic matrix composite body, which includes a combustor shell and the chute.

First claim

What is claimed is:

1. A method for fabricating a ceramic matrix composite chute, comprising:
forming a porous ceramic preform comprising a plurality of ceramic fibers;
forming an aperture in the porous ceramic preform;
enlarging the aperture into a chute shape by inserting a layup tool into the aperture; and
forming the porous ceramic preform into a ceramic matrix composite body, the ceramic matrix composite body comprising a combustor shell and a chute, wherein the combustor shell comprises a chamber defined by a wall of the combustor shell and the chute extends from the combustor shell towards a midline of the chamber of the combustor shell.

2. The method of claim 1 , wherein forming the porous ceramic preform comprises stacking a plurality of two-dimensional weaves.

3. The method of claim 2 , wherein forming the aperture in the porous ceramic preform comprises forming an opening in each two-dimensional weave and aligning the openings in the stacked plurality of two-dimensional weaves.

4. The method of claim 1 , wherein forming the porous ceramic preform comprises stacking a plurality of unidirectional tape layups.

5. The method of claim 4 , wherein forming the aperture in the porous ceramic preform comprises forming an opening in each unidirectional tape layup and aligning the openings in the stacked plurality of unidirectional tape layups.

6. The method of claim 1 , wherein forming the aperture in the porous ceramic preform comprises cutting the aperture into the porous ceramic preform.

7. The method of claim 1 , wherein forming the aperture in the porous ceramic preform comprises weaving the aperture into the porous ceramic preform.

8. The method of claim 1 , wherein forming the porous ceramic preform into the ceramic matrix composite body comprises treating the porous ceramic preform with one or more of a chemical vapor infiltration, a slurry infiltration, or a melt infiltration.

9. The method of claim 1 , wherein the plurality of ceramic fibers are braided.

10. A method for fabricating a ceramic matrix composite chute, comprising:
forming a ceramic preform into a frame for a combustor shell and a chute;
forming the ceramic preform into a ceramic matrix composite body, the ceramic matrix composite body comprising the combustor shell and the chute, wherein the combustor shell comprises a chamber defined by a wall of the combustor shell and the chute extends from the combustor shell towards a midline of the chamber of the combustor shell; and
enlarging an aperture in the ceramic preform with a layup tool.

11. The method of claim 10 , wherein the layup tool includes a cylinder, the aperture is enlarged when the cylinder is inserted into the aperture.

12. The method of claim 10 further comprising moving ceramic fibers in the ceramic preform with the layup tool when enlarging the aperture such that the ceramic fibers extend from the combustor shell into the chute in the ceramic matrix composite body.

13. The method of claim 10 , wherein forming the ceramic preform comprises forming the ceramic preform into the frame for the combustor shell and for a plurality of chutes, and, wherein the ceramic matrix composite body comprises the combustor shell and the chutes.

14. The method of claim 10 wherein forming the ceramic matrix composite body comprises one or more of a chemical vapor infiltration, a slurry infiltration, or a melt infiltration.

15. A method for fabricating a ceramic matrix composite chute, comprising:
forming a porous ceramic preform from a three-dimensional weave of ceramic fibers;
forming an aperture in the porous ceramic preform;
enlarging the aperture into a chute shape by inserting a layup tool into the aperture; and
forming the porous ceramic preform into a ceramic matrix composite body, the ceramic matrix composite body comprising a combustor shell and a chute, wherein the combustor shell comprises a chamber defined by a wall of the combustor shell and the chute extends from the combustor shell towards a midline of the chamber of the combustor shell.

16. The method of claim 15 , wherein forming the aperture in the porous ceramic preform comprises cutting the aperture into the porous ceramic preform.

17. The method of claim 15 , wherein forming the aperture in the porous ceramic preform comprises weaving the aperture into the porous ceramic preform.

18. The method of claim 15 , wherein enlarging the aperture into the chute shape by inserting the layup tool into the aperture comprises pressing the layup tool into the aperture until the chute shape becomes larger.

19. The method of claim 15 , wherein forming the porous ceramic preform into the ceramic matrix composite body comprises treating the porous ceramic preform with one or more of a chemical vapor infiltration, a slurry infiltration, or a melt infiltration.

20. The method of claim 15 , wherein the ceramic fibers are braided.

Assignees

• Rolls Royce Corp

Inventors

• Varney Bruce Edward

Classifications

• F23R3/007 Primary

  constructed mainly of ceramic components · CPC title

• B28B21/72

  Producing multilayer tubes · CPC title

• B28B21/98

  for reshaping, e.g. by means of reshape moulds · CPC title

• C04B35/71

  Ceramic products containing macroscopic reinforcing agents (C04B35/66 takes precedence {; infiltration of a porous ceramic matrix with a material forming a non-ceramic phase C04B41/00, reaction infiltration with Si in order to form SiC C04B35/573, in order to form Si3N4 C04B35/591}) · CPC title

• C04B38/0093

  Other features · CPC title