Automated Ceramic Matrix Composite Ply Layup

Patent metadata

Field	Value
Publication number	US-2017320785-A1
Application number	US-201615146132-A
Country	US
Kind code	A1
Filing date	May 4, 2016
Priority date	May 4, 2016
Publication date	Nov 9, 2017
Grant date	—

Abstract

Methods for forming ceramic matrix composite (CMC) components are provided. In one exemplary embodiment, a method comprises automatically laying up CMC plies. Laying up plies includes transferring a CMC ply to a layup tool; applying heat to the CMC ply; and stacking the CMC ply with at least one other CMC ply. In various embodiments, CMC plies may be laid up using an automated machine. In some embodiments, a CMC ply may be transferred to a layup tool using an automated machine and the CMC ply may be stacked with at least one other CMC ply using the automated machine.

First claim

1 . A method for forming a ceramic matrix composite (CMC) component, the method comprising:
forming pieces of a pre-impregnated CMC tape; drying the pieces of the pre-impregnated CMC tape to produce CMC plies; and automatically laying up the CMC plies, wherein laying up the CMC plies includes
transferring a CMC ply to a layup tool;
applying heat to the CMC ply via the layup tool; and
stacking the CMC ply with at least one other CMC ply.

2 . The method of claim 1 , further comprising, after applying heat to the CMC ply but before stacking the CMC ply with at least one other CMC ply, heating the CMC ply for a first period of time.

3 . The method of claim 2 , further comprising, after stacking the CMC ply with at least one other CMC ply, heating the stacked CMC plies for a second period of time.

4 . The method of claim 3 , wherein the CMC plies are laid up on a heated layup tool, wherein heating the CMC ply for the first period of time comprises covering the CMC ply for the first period of time, and wherein heating the stacked CMC plies for the second period of time comprises covering the stacked CMC plies for the second period of time.

5 . The method of claim 3 , further comprising, after heating the stacked CMC plies for the second period of time, removing the heat from the stacked CMC plies.

6 . The method of claim 1 , wherein transferring the CMC ply to the layup tool comprises transferring a plurality of CMC plies to the layup tool, wherein applying heat to the CMC ply comprises applying heat to the plurality of CMC plies, and wherein stacking the CMC ply comprises stacking the plurality of CMC plies.

7 . The method of claim 1 , further comprising, while applying heat to the CMC ply, molding the CMC ply to a desired contour.

8 . The method of claim 7 , wherein an automated machine molds the CMC ply to the desired contour.

9 . The method of claim 1 , wherein an automated machine transfers the CMC ply to the layup tool.

10 . The method of claim 1 , wherein an automated machine stacks the CMC ply with the at least one other CMC ply.

11 . The method of claim 1 , further comprising, after stacking the CMC ply with at least one other CMC ply, repeating transferring a CMC ply to the layup tool, applying heat to the CMC ply, and stacking the CMC ply with at least one other CMC ply.

12 . The method of claim 11 , wherein, as transferring, applying, and stacking are repeated, stacking the CMC ply with at least one other CMC ply includes stacking the CMC ply with previously stacked CMC plies.

13 . The method of claim 11 , wherein transferring a CMC ply to the layup tool, applying heat to the CMC ply, and stacking the CMC ply with at least one other CMC ply are repeated until a component preform is formed.

14 . The method of claim 13 , further comprising processing the component preform in an autoclave at an elevated temperature and an elevated pressure.

15 . The method of claim 14 , further comprising densifying the component preform.

16 . (canceled)

17 . A method for forming a ceramic matrix composite (CMC) component, the method comprising:
laying up CMC plies using an automated machine, wherein laying up the CMC plies includes
transferring a CMC ply to a layup tool;
applying heat to the CMC ply via the layup tool;
heating the CMC ply for a first period of time;
stacking the CMC ply with at least one other CMC ply; and
heating the stacked CMC plies for a second period of time, wherein the CMC plies are formed from pre-impregnated CMC tape.

18 . The method of claim 17 , wherein the CMC plies are formed from dried pre-impregnated CMC tape.

19 . The method of claim 17 , wherein transferring a CMC ply to the layup tool, applying heat to the CMC ply, heating the CMC ply for the first period of time, stacking the CMC ply with at least one other CMC ply, and heating the stacked CMC plies for the second period of time are repeated until a component preform is formed.

20 . A method for forming a ceramic matrix composite (CMC) component, the method comprising:
forming CMC plies from pre-impregnated CMC tape and laying up CMC plies, wherein laying up CMC plies includes
transferring a CMC ply to a layup tool using an automated machine;
applying heat to the CMC ply via the layup tool;
heating the CMC ply for a first period of time;
stacking the CMC ply with at least one other CMC ply using the automated machine; and
heating the stacked CMC plies for a second period of time.

21 . The method of claim 4 , wherein covering the CMC ply for the first period of time, and covering the stacked CMC plies for the second period of time is by a shrink wrap.

Assignees

• Gen Electric

Inventors

• Matsumoto Roger Lee Ken
• Garg Nitin

Classifications

• F01D5/284

  Selection of ceramic materials · CPC title

• C04B35/6342

  Polyvinylacetals, e.g. polyvinylbutyral [PVB] · CPC title

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title

• C04B2237/365

  Silicon carbide · CPC title

• F05D2230/31

  Layer deposition · CPC title