CERAMIC MATRIX COMPOSITE

• US 20140271161A1
• Filed: 12/05/2013
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Lazur, Andrew Joseph
• Granted Patent: US 9,726,025 B2
• Time in Patent Office: Days
• US Class Current: 415/200
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/5256 Two-dimensional, e.g. woven structures
• 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 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/573 obtained by reaction sintering or recrystallisation
• CPC Class Codes: C04B 35/62868 Boron nitride
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: F01D 5/14 Form or construction selecting particular materials, measures against erosion or corrosion F01D5/28
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F01D 9/02 Nozzles; Nozzle boxes; Stator blades; Guide conduits , e.g. individual nozzles nozzle boxes F01D9/047
• CPC Class Codes: Y10T 29/49316 Impeller making
• CPC Class Codes: Y10T 428/24124 Fibers
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component

Abstract

A novel ceramic matrix composite is disclosed for forming components that are operable in high temperature environments such those in gas turbine engines and the like. The ceramic matrix composite can include at least one layer of non-crimped fibers positioned substantially parallel to one another. A relatively small diameter elastic fiber can be constructed to stitch the non-crimped fibers together and a ceramic matrix may be deposited around the at least one layer of non-crimped fibers.

Claims

1. A ceramic matrix composite comprising:

at least one layer of non-crimped fibers positioned substantially parallel to one another;

a relatively small diameter elastic fiber constructed to stitch the non-crimped fibers together, and

a ceramic matrix deposited around the at least one layer of non-crimped fibers.

2. The ceramic matrix composite of claim 1, wherein the small elastic fiber is made from one of a polymer material, acrylic material and a carbon material.

3. The ceramic matrix composite of claim 1, wherein the small elastic fiber is removed from the non-crimped fibers prior to depositing the ceramic matrix.

4. The ceramic matrix composite of claim 3, wherein the small elastic fiber is removed by at least one of exposure to a liquid, exposure to a gas or exposure to heat in a vacuum.

5. The ceramic matrix composite of claim 1, wherein the non-crimped fibers comprise a monofilament having a cross sectional diameter between approximately 20 and 300 microns.

6. The ceramic matrix composite of claim 1, further comprising:

a plurality of layers of non-crimped fibers configured into a preform core with a desired shape.

7. The ceramic matrix composite of claim 6, wherein the plurality of layers are held in place with the relative small fiber.

8. The ceramic matrix composite of claim 6, wherein at least one layer includes a non-crimped fiber orientation that is different from a non-crimped fiber orientation of an adjacent layer.

9. The ceramic matrix composite of claim 1, wherein the non-crimped fibers are formed from one of silicon, silicon carbide, or carbon material.

10. The ceramic matrix composite of claim 1, wherein a finished component made from the ceramic matrix composite is operable in a gas turbine engine.

11. A gas turbine engine comprising:

a compression section;

a combustor section positioned downstream of the compression section;

a turbine section positioned downstream of the combustor section;

an exhaust section positioned downstream of the turbine section; and

a component positioned in one of the sections comprising;

a plurality of layers of non-crimped fibers, wherein each layer includes a plurality of non-crimped fibers positioned substantially parallel to one another;

a relatively small diameter fiber constructed to stitch the layers of non-crimped fibers together to form a preform core shape; and

a ceramic matrix processed to infiltrate the preform core shape and form a non-finished component.

12. The gas turbine engine of claim 11, wherein the small fiber is made from one of a polymer material, acrylic material and a carbon material.

13. The gas turbine engine of claim 11, wherein the small fiber is removed from the preform prior to the ceramic matrix infiltration.

14. The gas turbine engine of claim 11, wherein the non-crimped fibers comprise a monofilament having a cross sectional diameter between approximately 20 and 300 microns.

15. The gas turbine engine of claim 11, wherein at least one layer includes a non-crimped fiber orientation that is different from a non-crimped fiber orientation of an adjacent layer.

16. The gas turbine engine of claim 11, wherein the component includes at least one of a static turbine vane and a rotatable turbine blade.

17. A method comprising:

stitching plies of relatively large diameter non-crimped fibers together with relative small diameter fiber;

forming the plies of non-crimped fibers into a core preform shape; and

infiltrating the core preform with a ceramic matrix to form a non-finished ceramic matrix composite component.

18. The method of claim 17 further comprising:

coating the non-crimped fibers prior to the infiltrating with a material at least partially made from boron nitride.

19. The method of claim 17 further comprising:

removing the small fiber from the preform prior to the infiltrating by exposing the small fiber to at least one of a liquid, a gas or heat in a vacuum.

20. The method of claim 17 further comprising:

processing the non-finished ceramic matrix composite component to make a finished component that is operable in a gas turbine engine.

21. The method of claim 17 further comprising:

processing the non-finished ceramic matrix composite component with at least one of a machining, a grinding, a sanding and/or a coating operation.