Filament winding apparatus and method for ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-2016229756-A1
Application number	US-201415022521-A
Country	US
Kind code	A1
Filing date	Sep 9, 2014
Priority date	Sep 19, 2013
Publication date	Aug 11, 2016
Grant date	—

Abstract

An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).

First claim

1 . An apparatus for making a composite article, the apparatus comprising:
a monofilament feed track adapted to carry a first spaced array of ceramic monofilament strands; a fiber yarn feed track adapted to carry a second spaced array of fiber yarn tows impregnated with a plurality of glass particulates; a mandrel disposed at an end of the monofilament feed track and an end of the fiber yarn feed track, the mandrel adapted to wind together individual tows of the first spaced array of glass-impregnated fiber yarn tows and individual strands of the array of ceramic monofilament strands to form a dual-fiber weave; and a heater assembly disposed within or adjacent to the mandrel, the heater assembly adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).

2 . The apparatus of claim 1 , wherein the monofilament feed track comprises:
a plurality of monofilament spools having a corresponding plurality of ceramic monofilament strands; and a collimator disposed along the monofilament feed track between the plurality of monofilament spools and the mandrel.

3 . The apparatus of claim 2 , wherein the collimator is adapted to receive unspooled ones of the plurality of ceramic monofilament strands from the plurality of corresponding monofilament spools, and to separate the unspooled ones into the first spaced array of ceramic monofilament strands.

4 . The apparatus of claim 2 , wherein the plurality of ceramic monofilament strands comprises a plurality of silicon carbide (SiC) ceramic monofilament strands.

5 . The apparatus of claim 1 , wherein the fiber yarn feed track comprises:
a plurality of fiber yarn spools having a corresponding plurality of fiber yarn tows; and a slurry tank disposed along the fiber yarn feed track between the plurality of fiber yarn spools and the mandrel.

6 . The apparatus of claim 5 , wherein the slurry tank is adapted to receive unspooled ones of the plurality of fiber yarn strands from the plurality of corresponding fiber yarn spools, and to impregnate the unspooled ones with a plurality of glass particulates contained in the slurry tank.

7 . The apparatus of claim 5 , wherein the plurality of fiber yarn tows comprises at least one of: a plurality of silicon carbide (SiC) fiber yarn strands, a plurality of carbon fiber yarn strands, or mixtures thereof.

8 . The apparatus of claim 5 , wherein the slurry tank contains a slurry comprising a plurality of glass particulates and a binder suspended in a carrier liquid.

9 . The apparatus of claim 8 , wherein the plurality of glass particulates comprises at least one of: borosilicate glass particles, lithium aluminosilicate glass particles, barium magnesium aluminosilicate particles, and mixtures thereof.

10 . The apparatus of claim 1 , wherein the heater assembly comprises:
a resistance heater disposed within the mandrel.

11 . The apparatus of claim 1 , wherein the heater assembly comprises:
an energy beam generator disposed adjacent to the mandrel, the energy beam generator adapted to direct at least one energy beam toward the fiber yarn feed track.

12 . A method for making a composite article, the method comprising:
collimating a plurality of ceramic monofilaments into a first spaced array of ceramic monofilament strands; tensioning the first spaced array of ceramic monofilament strands; commingling the first spaced array of ceramic monofilament strands with a second array of fiber yarn tows, at least some of the fiber yarn tows impregnated with a plurality of glass particulates; heating the commingled first array of ceramic monofilament strands and second array of fiber yarn tows, thereby softening the plurality of glass particulates; winding the commingled glass monofilament strands and impregnated fiber yarn tows onto a mandrel; and consolidating the softened glass particulates, the fiber yarn tows, and the monofilament strands into a dual-fiber ceramic matrix composite (CMC) material.

13 . The method of claim 12 , wherein the consolidation step is performed at least in part by pressure from the tensioned array of monofilament strands acting on the fiber yarn tows and the softened glass particulates.

14 . The method of claim 12 , further comprising:
adhering a plurality of glass particulates to form at least some of the plurality of impregnated fiber yarn tows.

15 . The method of claim 12 , wherein the adhering step comprises:
passing at least some of the plurality of fiber yarn tows through a slurry of glass particulates and carrier liquid; and evaporating the carrier liquid from the fiber yarn tows to form the plurality of impregnated fiber yarn tows.

16 . The method of claim 12 , wherein the step of heating the array of fiber yarn tows comprises:
prior to the winding step, directing an energy beam toward the plurality of fiber yarn tows to soften the plurality of glass particulates.

17 . The method of claim 12 , wherein the step of heating the array of fiber yarn tows comprises:
during the winding step, heating a surface on or adjacent to the mandrel to soften the plurality of glass particulates.

18 . The method of claim 12 , wherein the plurality of ceramic monofilaments comprises a plurality of silicon carbide (SiC) glass monofilaments.

19 . The method of claim 12 , wherein the plurality of glass particulates comprises borosilicate glass particles, lithium aluminosilicate glass particles, barium magnesium aluminosilicate particles, and mixtures thereof.

20 . The method of claim 12 , wherein during at least one of the winding step and the consolidating step, the plurality of tensioned monofilament strands apply a pressure of at least about 550 MPa (about 80 ksi) to the fiber yarn tows and the softened glass particulates.

21 . The method of claim 12 , wherein a nominal diameter of each of the ceramic monofilament strands measures at least about 100 μm (about 0.0040 inches).

22 . The method of claim 12 , wherein a ratio of ceramic monofilament strands to fiber yarn tows is at least about 8:1.

23 . The method of claim 12 , wherein the ratio of ceramic monofilament strands to fiber yarn tows is at least about 10:1.

Assignees

• United Technologies Corp

Inventors

• Jarmon David C
• Tredway William K

Classifications

• C03C2214/02

  Fibres; Filaments; Yarns; Felts; Woven material · CPC title

• C03C14/002 Primary

  the non-glass component being in the form of fibres, filaments, yarns, felts or woven material · CPC title

• C03C2214/30

  Methods of making the composites · CPC title

• C04B35/82 Primary

  Asbestos; Glass; Fused silica · CPC title

• B28B1/52

  specially adapted for producing articles from mixtures containing fibres, {e.g. asbestos cement}(by wrapping on to mandrels B28B1/42) · CPC title