Method for manufacturing a CMC part

Patent metadata

Field	Value
Publication number	US-11897816-B2
Application number	US-201917054676-A
Country	US
Kind code	B2
Filing date	May 15, 2019
Priority date	May 15, 2018
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

A process for manufacturing a part made of a ceramic matrix composite material, includes coating an outer surface of a porous preform with a layer of a fugitive material to form a model of the part to be obtained, the fugitive material being wax or resin, the fugitive material layer in the model not exceeding the highest peak of surface undulations of the preform, and ceramic and/or carbon particles being present in the porosity of the preform, coating the model formed with a ceramic powder composition, heat treating the coated model to remove the fugitive material and form a ceramic shell mold by sintering of the ceramic powder composition, introducing a molten composition including silicon into the shell mold to obtain the part in the shell mold, the molten composition infiltrating the porosity of the preform to form the ceramic matrix, and separating the shell mold from the part obtained.

First claim

The invention claimed is:

1. A process for manufacturing a part made of a ceramic matrix composite material, comprising:
coating an outer surface of a porous preform with a layer of a fugitive material to form a model of the part to be obtained, the fugitive material being a wax or a resin, the fugitive material layer in the model not exceeding a highest peak of surface undulations of the porous preform, and ceramic and/or carbon particles being present in the porosity of the porous preform,
coating the model formed with a ceramic powder composition,
heat treating the coated model to remove the fugitive material and form a ceramic shell mold by sintering of the ceramic powder composition,
introducing a molten composition comprising silicon into the shell mold to obtain the part in the shell mold, the molten composition infiltrating the porosity of the porous preform to form the ceramic matrix, and
separating the shell mold from the part obtained.

2. The process as claimed in claim 1 , wherein the ceramic powder composition comprises: a mullite powder, a silicon carbide powder, a silicon nitride powder, a boron nitride powder, or a mixture thereof.

3. The process as claimed in claim 1 , wherein the porous preform is a woven fibrous preform obtained by three-dimensional weaving.

4. The process as claimed in claim 3 , wherein the porous preform is partially densified by a ceramic matrix phase.

5. The process as claimed in claim 1 , wherein the part is a turbomachine part.

6. A process for manufacturing a multilayer structure comprising:
manufacturing a part made of ceramic matrix composite material coated with a bonding layer comprising silicon by implementing a process comprising:
coating an outer surface of a porous preform with a layer of a fugitive material in order to form a model of the coated part to be obtained having dimensions of the coated part,
coating the model formed with a ceramic powder composition,
heat treating the coated model to remove the fugitive material and form a ceramic shell mold by sintering of the ceramic powder composition,
introducing a molten composition comprising silicon into the shell mold to obtain the coated part in the shell mold, the molten composition infiltrating the porosity of the porous preform to form the ceramic matrix and covering the outer surface to form the bonding layer, ceramic and/or carbon particles being present in the porosity of the porous preform, and
separating the shell mold from the coated part obtained, and

forming a protective coating on the bonding layer.

7. The process as claimed in claim 6 , wherein the ceramic powder composition comprises: a mullite powder, a silicon carbide powder, a silicon nitride powder, a boron nitride powder, or a mixture of thereof.

8. The process as claimed in claim 6 , wherein the thickness of the fugitive material layer in the model is greater than or equal to 10 μm, said thickness being measured at and from a highest peak of surface undulations of the porous preform.

9. The process as claimed in claim 6 , wherein the fugitive material is a wax or a resin.

10. The process as claimed in claim 6 , wherein the porous preform is a woven fibrous preform obtained by three-dimensional weaving.

11. The process as claimed in claim 6 , wherein the porous preform is partially densified by a ceramic matrix phase.

12. The process as claimed in claim 6 , wherein the coated part is a turbomachine part.

13. The process as claimed in claim 6 , wherein the protective coating is an environmental barrier.

Assignees

• Safran
• Safran Ceram
• Safran Aircraft Engines

Inventors

• Podgorski Michaël
• Dambrine Bruno Jacques Gérard
• Mendez Emilie Chantal Gisèle
• Zhang Wen
• Rappart Yvan
• Leleu Charles

Classifications

• C04B35/565 Primary

  based on silicon carbide · CPC title

• C04B35/185

  Mullite {3Al2O3-2SiO2} · CPC title

• C04B35/573

  obtained by reaction sintering {or recrystallisation} · CPC title

• C04B35/583

  based on boron nitride · CPC title

• C04B35/584

  based on silicon nitride · CPC title