PROCESS OF PRODUCING A COMPOSITE COMPONENT AND INTERMEDIATE PRODUCT THEREOF

• US 20080132398A1
• Filed: 12/04/2006
• Published: 06/05/2008
• Est. Priority Date: 12/04/2006
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Subramanian, Suresh, Carper, Douglas Melton, Kostar, Timothy Daniel, Steibel, James Dale
• Granted Patent: US 7,837,914 B2
• Time in Patent Office: Days
• US Class Current: 501/1
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/5268 Orientation of the fibers
• CPC Class Codes: C04B 2235/6028 Shaping around a core which is removed later
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: D03D 15/242 inorganic, e.g. basalt
• CPC Class Codes: D03D 15/44 with specific cross-section or surface shape
• CPC Class Codes: D03D 25/005 Three-dimensional woven fabrics
• CPC Class Codes: D10B 2101/08 Ceramic
• CPC Class Codes: D10B 2401/062 stiff, shape retention
• CPC Class Codes: D10B 2401/063 high strength
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs
• CPC Class Codes: F01D 5/284 Selection of ceramic materials
• CPC Class Codes: F05D 2300/2261 of silicon
• CPC Class Codes: F05D 2300/2283 of silicon
• CPC Class Codes: F05D 2300/614 Fibres or filaments
• CPC Class Codes: Y10T 428/24058 including grain, strips, or filamentary elements in respective layers or components in angular relation
• CPC Class Codes: Y10T 428/24107 including mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24132 : including grain, strips, or filamentary elements in different layers or components parallel
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/24157 : Filled honeycomb cells [e.g., solid substance in cavities, etc.]
• CPC Class Codes: Y10T 428/249929 : Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/2973 : Particular cross section
• CPC Class Codes: Y10T 442/3195 : Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/322 : Warp differs from weft

Abstract

A preform architecture and process for producing composite materials, and particularly CMC components. The process entails producing a composite component having a matrix material reinforced with a three-dimensional preform. The process includes producing first and second sets of tows containing filaments. Each tow of the first set has a predetermined cross-sectional shape and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material. The preform is then fabricated from the first and second sets of tows, in which the second set of tows are transverse to the first set of tows, adjacent tows of the second set are spaced apart to define interstitial regions therebetween, and the cross-sectional shapes of the first set of tows are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.

Claims

1. A process of producing a composite component comprising a matrix material reinforced with a three-dimensional preform, the process comprising the steps of:

producing a first set of tows in which each tow contains a plurality of substantially parallel filaments, has a predetermined cross-sectional shape, and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material;

producing at least a second set of tows in which each tow contains a plurality of substantially parallel filaments; and

then

fabricating the three-dimensional preform to comprise the first and second sets of tows, in which the tows of the second set are transverse to the tows of the first set, adjacent tows of the second set are spaced apart to define interstitial regions therebetween having a cross-sectional shape, and the predetermined cross-sectional shapes of the tows of the first set are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.

2. The process according to claim 1, further comprising the steps of:

heating the preform to remove the temporary matrix material on the first set of tows so as to yield substantially uniform spacing between the first and second sets of tows; and

then

infiltrating the spacing between the first and second sets of tows to form the composite component and so that the preform is within the matrix material.

3. The process according to claim 2 wherein, during the heating of the preform, the temporary matrix material burns off without leaving any amount of residue on the tows of the first set that would reduce the mechanical properties of the composite component.

4. The process according to claim 1, wherein the filaments and the matrix material are ceramic materials.

5. The process according to claim 1, wherein the preform is fabricated such that the first set of tows are static tows and the second set of tows are dynamic tows of the preform.

6. The process according to claim 5, wherein the tows of the first set are substantially straight and the tows of the second set are interlaced with the tows of the first set.

7. The process according to claim 1, wherein the preform has a woven architecture.

8. The process according to claim 1, wherein the preform has a braided architecture.

9. The process according to claim 1, wherein the tows of the first set are produced by a pultrusion process.

10. The process according to claim 1, wherein the tows of the first set are produced by a process during which the tows of the first set are impregnated with the temporary matrix material.

11. The preform produced by the process of claim 1.

12. The composite component produced by the process of claim 2.

13. The composite component according to claim 12, wherein the component is a ceramic matrix composite component of a gas turbine engine.

14. A process of producing a gas turbine engine component comprising a ceramic matrix material reinforced with a three-dimensional preform, the process comprising the steps of:

producing a first set of tows in which each tow contains a plurality of substantially parallel ceramic filaments has a predetermined cross-sectional shape, and is embedded within a temporary matrix material formed of a polymeric material that is not the ceramic matrix material or a precursor of the ceramic matrix material;

producing at least a second set of tows in which each tow contains a plurality of substantially parallel filaments;

fabricating the three-dimensional preform to comprise the first and second sets of tows, in which the first set of tows are static tows, the second set of tows are dynamic tows and transverse to the tows of the first set, adjacent tows of the second set are spaced apart to define interstitial regions therebetween having a cross-sectional shape, and the predetermined cross-sectional shapes of the tows of the first set are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions;

heating the preform to remove the temporary matrix material on the first set of tows so as to yield substantially uniform spacing between the first and second sets of tows; and

infiltrating the spacing between the first and second sets of tows to form the gas turbine engine component, wherein the preform is within the ceramic matrix material and the temporary matrix material is removed during the heating of the preform without leaving any amount of residue on the tows of the first set that would reduce the mechanical properties of the gas turbine engine component.

15. The process according to claim 14, wherein the tows of the first set are substantially straight and the tows of the second set are interlaced with the tows of the first set.

16. The process according to claim 14, wherein the preform has a woven architecture.

17. The process according to claim 14, wherein the preform has a braided architecture.

18. The process according to claim 14, wherein the tows of the first set are produced by a pultrusion process.

19. The process according to claim 14, wherein the tows of the first set are produced by a process during which the tows of the first set are impregnated with the temporary matrix material.

20. The gas turbine engine component produced by the process of claim 14.