Granulated feedstock for additively manufacturing ceramic components

Patent metadata

Field	Value
Publication number	US-12466107-B2
Application number	US-202318451321-A
Country	US
Kind code	B2
Filing date	Aug 17, 2023
Priority date	Aug 17, 2023
Publication date	Nov 11, 2025
Grant date	Nov 11, 2025

Abstract

Methods for manufacturing a ceramic matrix composite (CMC) component are provided. The method may include building a plurality of successive layers of the ceramic component through a selective solidification of a composite feedstock comprising a plurality of composite granules and densifying the ceramic component through infiltration with silicon. Each of the plurality of composite granules comprises one or more silicon carbide particles and one or more carbon particles. Composite feedstocks are also provided, which may include a plurality of composite granules with each of the plurality of composite granules comprises one or more silicon carbide particles and one or more carbon particles.

First claim

We claim:

1 . A method for manufacturing a ceramic matrix composite (CMC) component, the method comprising:
building a plurality of successive layers of the CMC component through a selective solidification of a composite feedstock comprising a plurality of composite granules, wherein each of the plurality of composite granules comprises one or more silicon carbide particles and one or more carbon particles, and wherein the composite feedstock comprises one or more of Mo, W, V, Ti, B 4 C, VC, MoC, or TiC in one or more of the composite granules or as pellets combined with the composite granules; and densifying the CMC component through infiltration with silicon.

2 . The method of claim 1 , wherein each of the plurality of composite granules further comprises a binder.

3 . The method of claim 2 , wherein each of the plurality of composite granules further comprises elemental silicon.

4 . The method of claim 1 , wherein the composite feedstock comprises from 50 to 95 weight percent silicon carbide.

5 . The method of claim 4 , wherein the composite feedstock comprises from 5 to 50 weight percent carbon.

6 . The method of claim 5 , wherein the composite feedstock comprises from 5 to 35 weight percent elemental silicon.

7 . The method of claim 1 , wherein the plurality of composite granules of the composite feedstock has an average pellet size of 5 μm to 75 μm.

8 . The method of claim 1 , further comprising combining a plurality of silicon carbide particles with a plurality of carbon particles to form the plurality of composite granules.

9 . The method of claim 8 , wherein the plurality of silicon carbide particles has an average particle size of 0.1 μm to 10 μm.

10 . The method of claim 9 , wherein the plurality of carbon particles has an average particle size of 0.1 μm to 10 μm.

11 . The method of claim 1 , wherein building the plurality of successive layers of the CMC component comprises solidifying the composite feedstock via binder jet printing or digital light processing.

12 . The method of claim 1 , wherein densifying the CMC component comprises melt infiltration with molten silicon or chemical vapor infiltration.

13 . The method of claim 1 , further comprising laying up one or more composite plies on the CMC component, and joining the one or more composite plies to form the CMC component.

14 . The method of claim 1 , wherein the CMC component is a turbine component.

15 . A method for manufacturing a ceramic matrix composite (CMC) component, the method comprising:
building a plurality of successive layers of the CMC component through a selective solidification of a composite feedstock, wherein the composite feedstock comprises a plurality of composite granules formed from the combination of one or more silicon carbide particles and one or more carbon particles, wherein the composite feedstock comprises from 5 to 95 weight percent silicon carbide and from 5 to 40 weight percent carbon, and wherein the composite feedstock comprises one or more of Mo, W, V, Ti, B4C, VC, MoC, or TiC in one or more of the composite granules or as pellets combined with the composite granules; and densifying the CMC component through infiltration with silicon or silicon-containing reactants.

16 . The method of claim 15 , wherein the composite feedstock further comprises from 5 to 35 weight percent silicon.

17 . The method of claim 15 , wherein the plurality of composite granules of the composite feedstock has an average pellet size of 5 μm to 75 μm.

18 . A composite feedstock comprising:
a plurality of composite granules, wherein each of the plurality of composite granules comprises one or more silicon carbide particles and one or more carbon particles; and one or more of Mo, W, V, Ti, B 4 C, VC, MoC, or TiC in one or more of the composite granules or as pellets combined with the composite granules; wherein the composite feedstock comprises from 5 to 95 weight percent silicon carbide and from 5 to 40 weight percent carbon; and wherein the plurality of composite granules of the composite feedstock has an average pellet size of 5 μm to 75 μm.

19 . The composite feedstock of claim 18 , wherein one or more of the plurality of composite granules further comprises a binder.

20 . The composite feedstock of claim 18 , wherein one or more of the plurality of composite granules further comprises elemental silicon.

Assignees

• Gen Electric

Inventors

• Mcguigan Henry Charles
• Navojosky William Francis
• Sarrafi-Nour Reza

Classifications

• B28B1/008

  made from two or more materials having different characteristics or properties (casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00) · CPC title

• B28B1/004

  Devices for shaping artificial aggregates from ceramic mixtures or from mixtures containing hydraulic binder (from slag C04B5/00; composition of artificial aggregates C04B18/02) · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• F01N3/0222

  the structure being monolithic, e.g. honeycombs · CPC title