Method for manufacturing a part made from CMC

Patent metadata

Field	Value
Publication number	US-12110256-B2
Application number	US-201917265359-A
Country	US
Kind code	B2
Filing date	Jul 23, 2019
Priority date	Aug 3, 2018
Publication date	Oct 8, 2024
Grant date	Oct 8, 2024

Abstract

A process for manufacturing a part made of composite material with a matrix at least predominantly made of ceramic includes producing a fibrous structure by three-dimensional or multilayer weaving; shaping the fibrous structure to form a fibrous preform core; depositing an interphase on the fibers of the preform core; consolidating the preform core by partial densification of the core including the formation of a matrix phase by chemical vapor infiltration or by a liquid process; depositing a powder of ceramic particles in the porosity of the preform core; draping one or more layers of pre-impregnated non-woven fibers over all or part of the outer surface of the preform core; heat treatment of the preform core and of the pre-impregnated layer(s) to form a hybrid fibrous preform; further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon to obtain a ceramic matrix composite part.

First claim

The invention claimed is:

1. A process for manufacturing a part made of a composite material with a matrix at least predominantly made of ceramic, the process comprising:
producing a fibrous structure by three-dimensional or multilayer weaving;
shaping the fibrous structure to form a fibrous preform core;
depositing an interphase on the fibers of the preform core;
consolidating the preform core by partial densification of said core comprising the formation of a matrix phase by chemical vapor infiltration or by a liquid process;
depositing a powder of ceramic particles in a porosity of the preform core;
wherein, said process comprises, after the steps of producing, shaping, depositing, consolidating and depositing, the following steps:
draping one or more layers of pre-impregnated non-woven fibers over all or part of the outer surface of the preform core;
performing a heat treatment of the preform core and of the pre-impregnated layer(s) to form a hybrid fibrous preform;
further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon in order to obtain a ceramic matrix composite part.

2. The process as claimed in claim 1 , wherein the fibrous structure intended to form the preform core is woven with silicon carbide fiber threads or carbon fibers.

3. The process as claimed in claim 1 , wherein the interphase consists of pyrolytic carbon or of boron nitride.

4. The process as claimed in claim 1 , wherein, during consolidation, the matrix phase is formed in the preform core by chemical vapor infiltration, the matrix phase corresponding to a silicon carbide matrix or a self-healing matrix.

5. The process as claimed in claim 1 , further comprising, after the consolidation of the preform core, machining the preform core.

6. The process as claimed in claim 1 , wherein the ceramic material of the particles deposited in the porosity of the preform core is selected from one of the following materials or a mixture of the following materials: silicon carbide, silicon nitride, titanium silicide, boron carbide and carbon.

7. The process as claimed in claim 1 , wherein the pre-impregnated non-woven layer(s) are formed from silicon carbide or carbon carbide fiber threads.

8. The process as claimed in claim 1 , wherein the pre-impregnated non-woven layers are unidirectional layers of continuous fibers or layers of discontinuous fibers.

9. The process as claimed in claim 1 , wherein the non-woven layers are pre-impregnated with a carbon or silicon carbide precursor resin, the heat treatment comprising a polymerization treatment of the resin and a pyrolysis treatment to convert the precursor to carbon or to silicon carbide.

10. A method comprising performing the process as claimed in claim 1 to the manufacture of a gas turbine blade, nozzle or combustor.

11. The process as claimed in claim 1 , wherein the depositing the powder of ceramic particles in the porosity of the preform core comprises impregnating the preform core with a slurry containing at least one powder of ceramic particles.

12. The process as claimed in claim 1 , wherein the slurry further comprises one or more organic binders.

13. A process for manufacturing a ceramic matrix composite part with a matrix at least predominantly made of ceramic, the process comprising, in order:
producing a fibrous structure by three-dimensional or multilayer weaving;
shaping the fibrous structure to form a fibrous preform core;
depositing an interphase on the fibers of the preform core;
consolidating the preform core by partial densification of said core comprising the formation of a matrix phase by chemical vapor infiltration or by a liquid process, such that the preform core remains porous and has a residual porosity;
depositing a powder of ceramic particles in the residual porosity of the preform core;
draping one or more layers of pre-impregnated non-woven fibers over at least part of an outer surface of the preform core;
performing a heat treatment of the preform core and of the one or more layers of pre-impregnated non-woven fibers to form a hybrid fibrous preform;
further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon in order to obtain the ceramic matrix composite part.

Assignees

• Safran Ceram

Inventors

• Bouillon Eric
• Philippe Eric
• Garnier Gildas
• Carlin Maxime François Roger
• Verrilli Michael

Classifications

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title

• F01D5/284

  Selection of ceramic materials · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B2235/5268

  Orientation of the fibers · CPC title

• C04B2235/5244

  Silicon carbide · CPC title