MACHINABLE CMC INSERT

• US 20160356163A1
• Filed: 06/03/2016
• Published: 12/08/2016
• Est. Priority Date: 06/05/2015
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc), Rolls-Royce North American Technologies, Inc. (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc), Rolls-Royce North American Technologies, Inc. (Rolls-Royce Holdings Plc)
• Inventors: Freeman, Ted J., Nixon, Thomas D., Landwehr, Sean E., Sippel, Aaron D., Reinhart, Donald W.
• Granted Patent: US 10,465,534 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2237/36 Non-oxidic
• CPC Class Codes: C04B 2237/363 Carbon
• CPC Class Codes: C04B 2237/365 Silicon carbide
• CPC Class Codes: C04B 2237/368 Silicon nitride
• CPC Class Codes: C04B 2237/38 Fiber or whisker reinforced
• CPC Class Codes: C04B 2237/61 Joining two substrates of which at least one is porous by infiltrating the porous substrate with a liquid, such as a molten metal, causing bonding of the two substrates, e.g. joining two porous carbon substrates by infiltrating with molten silicon
• CPC Class Codes: C04B 2237/704 of one or more of the ceramic layers or articles
• CPC Class Codes: C04B 2237/72 Forming laminates or joined articles comprising at least two interlayers directly next to each other
• CPC Class Codes: C04B 2237/76 Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
• CPC Class Codes: C04B 2237/86 Joining of two substrates at their largest surfaces, one surface being complete joined and covered, the other surface not, e.g. a small plate joined at it's largest surface on top of a larger plate
• CPC Class Codes: C04B 35/573 obtained by reaction sintering or recrystallisation
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 37/005 consisting of glass or ceramic material
• CPC Class Codes: C04B 37/008 by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
• CPC Class Codes: F01D 25/246 Fastening of diaphragms or stator-rings
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F05D 2240/11 Shroud seal segments
• CPC Class Codes: F05D 2240/12 Fluid guiding means, e.g. vanes
• CPC Class Codes: F05D 2300/2261 : of silicon
• CPC Class Codes: F05D 2300/6033 : Ceramic matrix composites [CMC]
• CPC Class Codes: F05D 2300/611 : Coating
• CPC Class Codes: F05D 2300/614 : Fibres or filaments
• CPC Class Codes: F23R 2900/00018 : Manufacturing combustion chamber liners or subparts
• CPC Class Codes: F23R 3/002 : Wall structures F23R3/02 and F23R3/007 take precedence
• CPC Class Codes: F23R 3/007 : constructed mainly of ceramic components

Abstract

A ceramic matrix composite component and a ceramic insert, and a method for producing the same. The ceramic matrix composite component may include an exterior surface comprising silicon fibers in a silicon carbide matrix. The insert may include a continuous porosity bonded to the exterior surface of the ceramic matrix composite component. The silicon carbide matrix of the ceramic matrix composite component may extend into the porosity of the ceramic insert to bond the ceramic insert to the ceramic matrix composite component.

Claims

1. An assembly for use in a gas turbine engine, the assembly comprising

a ceramic matrix composite component, having an exterior surface, comprising silicon carbide fibers in a silicon carbide matrix, and

a ceramic insert having continuous porosity bonded to the exterior surface of the ceramic matrix composite component,

wherein the silicon carbide matrix of the ceramic matrix composite extends into the porosity of the ceramic insert to bond the ceramic insert to the ceramic matrix composite component.

2. The assembly of claim 1, wherein the ceramic insert is sandwiched between the ceramic matrix composite component and a metallic component in a gas turbine engine.

3. The assembly of claim 1, wherein the ceramic matrix composite component comprises a first silicon concentration and the insert comprises a second silicon concentration, the second silicon concentration lower than the first silicon concentration.

4. The assembly of claim 3, wherein the ceramic insert comprises an exterior surface with between about 80% and about 100% silicon carbide by volume.

5. The assembly of claim 1, wherein the ceramic insert comprises a resin char comprising silicon ceramic material, chopped carbon fibers, chopped silicon carbide fibers or a combination thereof.

6. The assembly of claim 1, wherein the ceramic insert comprises a pressed powder comprising silicon carbide powder and a binding agent.

7. The assembly of claim 1, wherein insert comprises a ceramic material comprising silicon carbide.

8. The assembly of claim 1, wherein the ceramic insert comprises a reticulated foam having a continuous porosity.

9. The assembly of claim 1, wherein the ceramic matrix composite component comprises a blade track, a vane, a blade, a combustor tile, an exhaust tail cone, or a combination thereof.

10. The assembly of claim 1, wherein in the ceramic matrix composite component comprises a recess along the exterior surface for mating with the insert.

11. The assembly of claim 1, wherein the ceramic matrix composite component comprises a blade track segment comprising a recess along the exterior surface.

12. The assembly of claim 11, wherein the ceramic insert comprises a dovetail post arranged to mate with the recess of the blade track segment.

13. The assembly of claim 11, wherein the ceramic insert comprises an positioning tab for mating with the recess of the blade track segment.

14. The assembly of claim 1, wherein at least of a portion of the ceramic insert and the ceramic matrix composite comprise an overwrap of a ply of fabric.

15. The assembly of claim 14, wherein the ply of fabric is covering at least a portion of the ceramic insert and the ceramic preform.

16. The assembly of claim 15, wherein the ply of fabric comprises silicon-carbide fibers.

17. A method of forming an insert for use in a gas turbine engine, the method comprising

providing a ceramic preform comprising silicon carbide fibers,

positioning a ceramic insert against the ceramic preform, and

co-infilitrating the insert and the ceramic preform with silicon metal or silicon alloy to form a silicon carbide matrix extending from within the ceramic preform to within the insert thereby joining the insert to the ceramic preform.

18. The method of claim 17, wherein the co-infiltrating the insert and the ceramic preform further comprises chemical vapor infiltration, chemical vapor deposition, slurry infiltration, polymer impregnation and pyrolysis, or a combination thereof.

19. The method of claim 17, further comprising pressing a powder to form the insert, wherein the powder comprises silicon, silicon carbide, or a combination thereof.

20. The method of claim 19, further comprising adding a polymeric binder to the powder, placing a ply of fabric to cover at least a portion of the insert and the ceramic preform, and machining the insert.