Ply, method for manufacturing ply, and method for manufacturing article with ply

Patent metadata

Field	Value
Publication number	US-9926796-B2
Application number	US-201514811351-A
Country	US
Kind code	B2
Filing date	Jul 28, 2015
Priority date	Jul 28, 2015
Publication date	Mar 27, 2018
Grant date	Mar 27, 2018

Abstract

A method for manufacturing a ply is disclosed. The method includes printing the ply, the ply including a near net shape and a ceramic matrix composite nonwoven material. A ply is disclosed wherein the near net shape is a predetermined layer of an article. A method for manufacturing an article is also disclosed. The method includes printing a first ply and a second ply. The first ply includes a first near net shape and a first ceramic matrix composite nonwoven material, and the second ply includes a second near net shape and a second ceramic matrix composite nonwoven material. The method further includes applying the second ply to the first ply, and consolidating the first ply and the second ply.

First claim

What is claimed is:

1. A method for manufacturing a ply, comprising:
printing the ply, the ply including a near net shape and a ceramic matrix composite nonwoven material,
wherein printing the ply includes:
extruding a coated pre-impregnated tow by a continuous filament fabrication process onto a printing bed of a printer, the coated pre- impregnated tow including:
ceramic matrix composite fibers;
ceramic matrix composite particles;
carbon particulates; and
a material selected from the group consisting of solvents, resins, alcohols, and combinations thereof; and

heating the coated pre-impregnated tow while extruding the coated pre-impregnated tow by heating the printing bed onto which the coated pre-impregnated tow is extruded, the heating the coated pre-impregnated tow partially curing the coated pre-impregnated tow.

2. The method of claim 1 , wherein printing includes the use of a three-dimensional continuous fiber placement printer.

3. The method of claim 1 , wherein the nonwoven material is a unidirectional tape.

4. The method of claim 3 , wherein the near net shape is a predetermined layer of a turbine component.

5. The method of claim 4 , wherein the turbine component is an airfoil.

6. The method of claim 5 , wherein the turbine component is a nozzle.

7. A method for manufacturing an article, comprising:
printing a first ply, the first ply including a first near net shape and a first ceramic matrix composite nonwoven material;
printing a second ply, the second ply including a second near net shape and a second ceramic matrix composite nonwoven material;
applying the second ply to the first ply, applying the second ply to the first ply including transferring the second ply manually or mechanically to the first ply; and
consolidating the first ply and the second ply,
wherein printing the first ply and printing the second ply include:
extruding a coated pre-impregnated tow by a continuous filament fabrication process onto a printing bed of a printer, the coated pre- impregnated tow including:
ceramic matrix composite fibers;
ceramic matrix composite particles;
carbon particulates; and
a material selected from the group consisting of solvents, resins, alcohols, and combinations thereof; and

heating the coated pre-impregnated tow while extruding the coated pre-impregnated tow by heating the printing bed onto which the coated pre-impregnated tow is extruded, the heating the coated pre-impregnated tow partially curing the coated pre-impregnated tow.

8. The method of claim 7 , wherein printing the first ply and printing the second ply includes the use of a three-dimensional continuous fiber placement printer.

9. The method of claim 7 , wherein the first near net shape and the second near net shape are adjacent predetermined layers of an article.

10. The method of claim 9 , wherein the article is a turbine component.

11. The method of claim 10 , wherein the turbine component is an airfoil.

12. The method of claim 11 , wherein the turbine component is a nozzle.

13. The method of claim 7 , wherein consolidating the first ply and the second ply includes a technique selected from the group consisting of autoclaving, burning out, local heat treatment, inductive heating, and combinations thereof.

14. The method of claim 1 , wherein heating the coated pre-impregnated tow while extruding the coated pre-impregnated tow includes heating with a heater element disposed in the printing bed.

15. The method of claim 7 , wherein heating the coated pre-impregnated tow while extruding the coated pre-impregnated tow includes heating with a heater element disposed in the printing bed.

16. The method of claim 1 , wherein the ceramic matrix composite particles include a largest dimension of no more than about 20 microns.

17. The method of claim 1 , wherein the carbon particulates include elemental carbon.

Assignees

• Gen Electric

Inventors

• Kittleson Jacob John

Classifications

• C04B2237/343

  Alumina or aluminates · CPC title

• F01D5/284

  Selection of ceramic materials · CPC title

• F05D2230/51

  in a modular way, e.g. using several identical or complementary parts or features · CPC title

• F01D9/041 Primary

  using blades (F01D5/148 takes precedence) · CPC title

• B33Y80/00 Primary

  Products made by additive manufacturing · CPC title