CVD functionalized particles for CMC applications

Patent metadata

Field	Value
Publication number	US-12330994-B2
Application number	US-202117390072-A
Country	US
Kind code	B2
Filing date	Jul 30, 2021
Priority date	Jul 30, 2021
Publication date	Jun 17, 2025
Grant date	Jun 17, 2025

Abstract

A method of manufacturing ceramic matrix composites includes producing chemical vapor deposition functionalized ceramic particles before injecting the functionalized ceramic particles into the CMC fabric. The functionalized ceramic particles are mixed with a binder solution and then dispensed into voids present between adjacent tows of the CMC fabric. Injecting the particles in the center of the voids reduces the size and volume fraction of the voids/defects, improving the homogeneity of surface texture, homogeneity of microstructure, and part model shape conformity.

First claim

The invention claimed is:

1. A method of forming a ceramic matrix composite component, the method comprising:
forming a plurality of ceramic fiber plies;
selectively applying functionalized ceramic particles into voids within each of the plurality of ceramic fiber plies;
laying up and debulking a stack of the plurality of ceramic fiber plies including the functionalized ceramic particles; and
subsequently densifying the stack of ceramic fiber plies;
wherein the functionalized ceramic particles are produced by coating base ceramic particles with a first chemical compound through a chemical vapor deposition or chemical vapor infiltration process;
wherein the first chemical compound is one or more of silicon carbide (SiC), boron nitride (BN), silicon boron nitride (SiBN), carbon (C), boron carbide (B 4 C), aluminum nitride (AlN), aluminum oxide (Al 2 O 3 ), zirconium dioxide (ZrO 2 ), silicon nitride (Si 3 N 4 ), silicon dioxide (SiO 2 ), and silicon oxycarbide (SiOC).

2. The method of claim 1 and further comprising coating the base ceramic particles with a second chemical compound through a chemical vapor deposition or chemical vapor infiltration process.

3. The method of claim 2 , wherein the first chemical compound is a same or different chemical compound than the second chemical compound.

4. The method of claim 1 , wherein the base ceramic particles are one or more of silicon carbide, boron carbide, silicon nitride, silicon, carbon, aluminum oxide, and hafnium oxide.

5. The method of claim 1 , wherein the step of selectively applying the functionalized ceramic particles comprises applying a mixture of the functionalized ceramic particles and a liquid binder into the voids within each ceramic fiber ply.

6. The method of claim 5 , wherein the liquid binder is one or more of a polyvinyl alcohol and water mixture and a polyvinyl butyral and ethanol mixture.

7. The method of claim 1 , wherein the step of densifying the stack of ceramic fiber plies comprises one or more of a chemical vapor infiltration, chemical vapor deposition, melt infiltration, and polymer infiltration and pyrolysis process.

8. The method of claim 1 , wherein the ceramic fiber plies are formed from silicon carbide fibers.

Assignees

• Raytheon Tech Corp
• Rtx Corp

Inventors

• Lenz Brendan M
• Frith Sarah A
• Sudre Olivier H

Classifications

• C04B35/62844

  Coating fibres · CPC title

• C04B2235/616

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

• C04B2235/3244

  Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B2235/422

  Carbon · CPC title