Machinable cmc insert

Patent metadata

Field	Value
Publication number	US-2016356499-A1
Application number	US-201615172975-A
Country	US
Kind code	A1
Filing date	Jun 3, 2016
Priority date	Jun 5, 2015
Publication date	Dec 8, 2016
Grant date	—

Abstract

An assembly comprising a ceramic matrix composite component, a ceramic insert, and a ply and a method for producing the same. The ceramic matrix composite component may comprise silicon carbide fibers in a silicon carbide matrix. The ceramic inset may be adjacent to the ceramic matrix composite component. The ply may at least partially cover the ceramic insert such that the ceramic insert may be sandwiched between the ply and the ceramic matrix composite component, and the ply may extend beyond the ceramic insert in at least one direction so that the ply is joined to the ceramic matrix composite. The ply may comprise at least one layer of silicon carbide fibers or carbon fibers in a silicon carbide matrix.

First claim

What is claimed is:

1 . An assembly for use in a gas turbine engine, the assembly comprising
a ceramic matrix composite component comprising silicon carbide fibers in a silicon carbide matrix, a ceramic insert adjacent to the ceramic matrix composite component, and a ply at least partially covering the ceramic insert such that the ceramic insert is sandwiched between the ply and the ceramic matrix composite component, and the ply extending beyond the ceramic insert in at least one direction so that the ply is joined to the ceramic matrix composite, wherein the ply comprises at least one layer of silicon carbide fibers or carbon fibers in a silicon carbide matrix.

2 . The assembly of claim 1 , wherein the ceramic insert comprises a resin char comprising silicon ceramic material, chopped carbon fibers, chopped silicon carbide fibers, or a combination thereof.

3 . The assembly of claim 1 , wherein the ceramic insert comprises a pressed powder comprising silicon carbide powder and a binding agent.

4 . The assembly of claim 1 , wherein ceramic insert comprises a ceramic material comprising silicon carbide.

5 . The assembly of claim 1 , wherein the ceramic insert comprises a reticulated foam having a continuous porosity.

6 . The assembly of claim 1 , wherein the ceramic matrix composite component comprises a blade track, a vane, a blade, a combustor tile, an exhaust tail cone, an exhaust liner flap, or a combination thereof.

7 . The assembly of claim 6 , wherein in the ceramic matrix composite component comprises a recess along the exterior surface with the insert being in the recess for mating with the insert.

8 . The assembly of claim 7 , wherein the ceramic matrix composite component comprises a blade track segment comprises a recess along the exterior surface.

9 . The assembly of claim 7 , wherein the ceramic insert comprises a dovetail post arranged to mate with the recess of the blade track segment.

10 . The assembly of claim 7 , wherein the ceramic insert comprises an positioning tab for mating with the recess of the blade track segment.

11 . A method of joining an insert to a ceramic matrix composite component for use in a gas turbine engine, the method comprising
providing a ceramic preform comprising silicon carbide fibers, positioning a ceramic insert adjacent to the ceramic preform, covering at least a portion of the insert and at least a portion of the ceramic preform with a ply comprising silicon carbide fibers, and co-infiltrating the ceramic preform and the ply with silicon metal or silicon alloy to form a silicon carbide matrix that extends through the ceramic preform and the ply.

12 . The method of claim 11 , wherein co-infiltrating comprises chemical vapor infiltration, chemical vapor deposition, slurry infiltration, polymer impregnation and pyrolysis, or a combination thereof.

13 . The method of claim 11 , further comprising depositing a pre-ceramic polymer along an exterior surface of the ceramic preform, and positioning the ceramic insert comprises sandwiching the pre-ceramic polymer between the insert and the ceramic preform.

14 . The method of claim 13 , wherein the pre-ceramic polymer resin char further comprises any ceramic phases, SiC, transition metals, transition metal borides, transition metal silicides, or combinations thereof.

15 . The method of claim 13 , further comprising heating the assembly to char the resin and produce a solid ceramic material.

16 . The method of claim 15 , wherein heating is performed at a temperature between about 1300° C. and about 1500° C.

17 . The method of claim 16 , further comprising infiltrating the ceramic preform and the insert with silicon metal, liquid silicon, silicon alloy, silicon carbide, or a combination thereof.

18 . The method of claim 13 , further comprising placing a ply of fabric to cover at least a portion of the insert and the ceramic preform.

19 . The method of claim 18 , wherein the ply of fabric comprises silicon carbide fibers.

20 . The method of claim 13 , further comprising machining the insert.

Assignees

• Rolls Royce Nam Tech Inc
• Rolls Royce Corp

Inventors

• Freeman Ted J
• Nixon Thomas D
• Landwehr Sean E
• Sippel Aaron D
• Reinhart Donald W

Classifications

• F05D2300/611

  Coating · CPC title

• F23R3/007 Primary

  constructed mainly of ceramic components · CPC title

• F05D2230/314

  by chemical vapour deposition · CPC title

• F01D5/284

  Selection of ceramic materials · CPC title

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title