Reinforced ceramic matrix composite and method of manufacture

Patent metadata

Field	Value
Publication number	US-2021188717-A1
Application number	US-201916723360-A
Country	US
Kind code	A1
Filing date	Dec 20, 2019
Priority date	Dec 20, 2019
Publication date	Jun 24, 2021
Grant date	—

Abstract

A method of making a ceramic matrix composite is disclosed. According to the method, a first preform comprising fibers is formed, and a second preform including a helical surface portion is inserted into the first preform. The first preform with the inserted second preform is infiltrated with a matrix material comprising a ceramic to form the ceramic matrix composite. A ceramic matrix composite is also disclosed. The ceramic matrix composite includes a first portion including a matrix comprising a ceramic, and a reinforcement including fibers derived from the first preform in the matrix. A second portion including a helical surface portion interface with the first portion is disposed within the first portion.

First claim

What is claimed is:

1 . A method of making a ceramic matrix composite, comprising:
forming a first preform comprising fibers; inserting a second preform including a helical surface portion into the first preform; and infiltrating a matrix material comprising a ceramic into the first preform to form the ceramic matrix composite.

2 . The method of claim 1 , wherein the first preform comprises a three-dimensional woven fiber preform or a stacked fiber layup.

3 . The method of claim 2 , wherein the first preform comprises a stacked layup of fibers including a Z-axis perpendicular to layers in the stacked layup, and the second preform is inserted with a helical axis of said helical surface portion arranged parallel to the Z-axis.

4 . The method of claim 1 , further comprising rotating the second preform about an axis of the helix in a rotational direction that promotes advancement of the helical surface through the first preform.

5 . The method of claim 4 , wherein axial movement of the second member with said insertion is equal to axial distance traveled by said helical surface portion in response to said rotation.

6 . The method of claim 1 , wherein the helical surface portion includes a portion arranged as a screw.

7 . The method of claim 1 , wherein the helical surface portion includes a helical portion arranged as a spring.

8 . The method of claim 7 , wherein the second preform is inserted into the first preform with the helical portion arranged as a spring being under tension, or under compression, or under neutral compression/tension.

9 . The method of claim 7 , further comprising compressing the first preform and inserted second preform.

10 . The method of claim 9 , wherein compression of the inserted second preform includes a helical compression of the portion of the second preform arranged as a spring.

11 . The method of claim 9 , wherein the second preform comprises ceramic fibers and an organic polymer resin, and the method includes pyrolyzing the organic polymer resin after compression and before infiltrating the matrix material.

12 . The method of claim 1 , further comprising compressing the first preform before infiltrating the matrix material.

13 . The method of claim 1 , wherein the second preform comprises ceramic fibers and an organic polymer resin, and the method includes pyrolyzing the organic polymer resin before infiltrating the matrix material.

14 . The method of claim 1 , further including applying an interface coating to the first preform, or to the second preform, or to the first preform and the second preform before infiltrating the matrix material.

15 . The method of claim 1 wherein infiltrating comprises chemical vapor infiltration, atomic layer deposition, polymer infiltration and pyrolysis, and/or melt infiltration.

16 . A ceramic matrix composite, comprising:
a first portion including a matrix comprising a ceramic, and a reinforcement comprising fibers in said matrix, said fibers derived from a first preform; and a second portion within the first portion, the second portion including a helical surface portion interface with the first portion.

17 . The ceramic matrix composite of claim 16 , wherein the second portion comprises a matrix comprising a ceramic, and a reinforcement comprising fibers in said matrix, said fibers derived from a second.

18 . The ceramic matrix composite of claim 16 , wherein the helical surface portion includes a portion arranged as a screw.

19 . The ceramic matrix composite of claim 16 , wherein the helical surface portion includes a helical portion arranged as a spring.

20 . A gas turbine engine component, comprising:
a first portion including a matrix comprising a ceramic, and a reinforcement comprising fibers in said matrix, said fibers derived from a first preform; and a second portion within the first portion, the second portion including a helical surface portion interface with the first portion.

Assignees

• United Technologies Corp

Inventors

• Kracum Michael R
• Jarmon David C

Classifications

• C04B2235/5224

  Alumina or aluminates · CPC title

• C04B2235/614

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

• F01D5/282

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title

• F23R3/007

  constructed mainly of ceramic components · CPC title