MACHINABLE CMC INSERT

• US 20160356164A1
• 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 10,472,976 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29L 2031/7504 Turbines
• CPC Class Codes: F01D 25/005 Selecting particular materials
• CPC Class Codes: F01D 25/246 Fastening of diaphragms or stator-rings
• CPC Class Codes: F01D 5/284 Selection of ceramic materials
• CPC Class Codes: F02K 1/04 Mounting of an exhaust cone in the jet pipe
• 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: F23M 2900/05004 Special materials for walls or lining
• CPC Class Codes: F23R 2900/00018 Manufacturing combustion chamber liners or subparts
• CPC Class Codes: F23R 3/007 constructed mainly of ceramic components

Abstract

An assembly comprising a ceramic matrix composite component, a monolithic insert, and a polymer char and a method for producing the same. The ceramic matrix composite component may include an exterior surface, with the monolithic insert bonded to the exterior surface of the ceramic matrix composite component. The polymer char may be sandwiched between the monolithic insert and the exterior surface of the ceramic matrix composite that may bond the monolithic 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,

a monolithic insert bonded to the exterior surface of the ceramic matrix composite component, and

a polymer char sandwiched between the monolithic insert and the exterior surface of the ceramic matrix composite component that bonds the monolithic insert to the ceramic matrix composite component.

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

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

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

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

6. 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.

7. The assembly of claim 6, wherein in the ceramic matrix composite component comprises a recess along the exterior surface for mating with the insert.

8. The assembly of claim 7, wherein the ceramic matrix composite component comprises a blade track segment with a recess along the exterior surface.

9. The assembly of claim 8, wherein the monolithic insert comprises a dovetail post arranged to mate with the recess of the blade track segment.

10. The assembly of claim 8, wherein the monolithic insert comprises a positioning tab for mating with the recess of the blade track segment.

11. The assembly of claim 1, further comprising a ply of fabric wrapped over at least a portion of the monolithic insert and the ceramic matrix composite.

12. The assembly of claim 11, wherein the ply of fabric comprises silicon-carbide fibers.

13. A method of joining an insert to a ceramic matrix composite component for use in a gas turbine engine, the method comprising

providing a ceramic preform comprising silicon carbide fibers,

depositing a pre-ceramic polymer along an exterior surface of the ceramic preform,

positioning the insert along the exterior surface of the ceramic preform such that the pre-ceramic polymer is sandwiched between the ceramic preform and the insert, and

heating the pre-ceramic polymer to form a polymer char that bonds the insert to the ceramic preform.

14. The method of claim 13, further comprising co-infiltrating the ceramic preform and the insert with liquid silicon, silicon alloy, silicon carbide, or a combination thereof.

15. The method of claim 14, wherein co-infiltrating comprises chemical vapor infiltration, chemical vapor deposition, slurry infiltration, melt infiltration, polymer impregnation and pyrolysis, or a combination thereof.

16. The method of claim 15, wherein the pre-ceramic polymer comprises ceramic phases, SiC, transition metals, transition metal borides, transition metal silicides, or combinations thereof.

17. The method of claim 13, wherein heating the assembly is performed at a temperature between about 1300°

C. and about 1500°

C.

18. The method of claim 13, further comprising placing a ply of fabric to cover at least a portion of the insert and the ceramic preform.

19. The method of claim 13, further comprising machining the insert after bonding the insert to the ceramic preform.

20. The method of claim 13, further comprising forming the polymer char and infiltrating the ceramic matrix composite component and the insert during, wherein forming the polymer char is performed contemporaneously with at least some portion of infiltration.