CERAMIC MATRIX COMPOSITE REINFORCED MATERIAL

• US 20180105471A1
• Filed: 09/05/2017
• Published: 04/19/2018
• Est. Priority Date: 10/19/2016
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Shi, Jun
• Granted Patent: US 10,894,746 B2
• Time in Patent Office: Days
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5228 Silica and alumina, including aluminosilicates, e.g. mullite
• CPC Class Codes: C04B 2235/5232 Silica or silicates other than aluminosilicates, e.g. quartz
• CPC Class Codes: C04B 2235/524 Non-oxidic, e.g. borides, carbides, silicides or nitrides
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/526 characterised by the length of the fibers
• 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 35/01 based on oxide ceramics
• CPC Class Codes: C04B 35/117 Composites
• CPC Class Codes: C04B 35/14 based on silica
• CPC Class Codes: C04B 35/16 based on silicates other than clay zircon C04B35/48
• CPC Class Codes: C04B 35/515 based on non-oxide ceramics
• CPC Class Codes: C04B 35/5607 based on refractory metal carbides
• 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: C04B 41/00 After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone conditioning of the materials prior to shaping C04B40/00; applying liquids or other fluent materials to surfaces, in general B05; grinding or polishing B24; apparatus or processes for treating or working shaped articles of clay or other ceramic compositions, slag or mixtures containing cementitious material B28B11/00; working stone or stone-like materials B28D; glazes, other than cold glazes, C03C8/00; etching, surface-brightening or pickling compositions C09K13/00
• CPC Class Codes: C23C 16/045 Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
• CPC Class Codes: C23C 16/325 : Silicon carbide

Abstract

A CMC article may include a CMC substrate defining a major surface and a plurality of CMC reinforcing pins at least partially embedded in the CMC substrate. Each CMC reinforcing pin of the plurality of CMC reinforcing pins defines a respective long axis. The respective long axes may be oriented at an angle substantially perpendicular to the major surface of the CMC substrate. A method may include inserting a plurality of CMC reinforcing pins into a major surface of a ceramic fiber preform. Each CMC reinforcing pin of the plurality of CMC reinforcing pins defines a respective long axis. As the plurality of CMC reinforcing pins are inserted into the major surface, the respective long axes may be oriented at an angle substantially perpendicular to the major surface. The method also includes forming a matrix of material within pores of the ceramic fiber preform to form a CMC article.

Claims

1. A method comprising:

inserting a plurality of ceramic matrix composite (CMC) reinforcing pins into a major surface of a ceramic fiber preform, wherein each CMC reinforcing pin of the plurality of CMC reinforcing pins defines a respective long axis, and wherein, as the plurality of CMC reinforcing pins are inserted into the major surface, the respective long axes are oriented at an angle substantially perpendicular to the major surface; and

forming a matrix of material within pores of the ceramic fiber preform to form a CMC component, wherein the matrix of material substantially surrounds the ceramic fiber preform and at least a portion of each respective CMC reinforcing pin.

2. The method of claim 1, wherein each respective CMC reinforcing pin of the plurality of CMC reinforcing pins includes ceramic fibers oriented substantially parallel to a lateral surface of the respective CMC reinforcing pin.

3. The method of claim 1, further comprising fabricating the plurality of CMC reinforcing pins.

4. The method of claim 3, wherein fabricating each CMC reinforcing pin of the plurality of CMC reinforcing pins comprises:

infiltrating a ceramic fiber bundle with liquid matrix material;

straightening the ceramic fiber bundle; and

forming a matrix from the liquid matrix material.

5. The method of claim 3, wherein fabricating each CMC reinforcing pin of the plurality of CMC reinforcing pins comprises:

positioning a ceramic fiber bundle in a straight mold;

infiltrating the ceramic fiber bundle with gaseous matrix material; and

cooling the ceramic fiber bundle.

6. The method of claim 1, wherein the plurality of CMC reinforcing pins are inserted substantially fully into the major surface.

7. The method of claim 1, wherein the plurality of CMC reinforcing pins are inserted partially into the major surface, wherein a first section of at least one CMC reinforcing pin of the plurality of CMC reinforcing pins is embedded in a coating on the major surface of the CMC component, and wherein a second section of the at least one CMC reinforcing pin of the plurality of CMC reinforcing pins is embedded in the CMC component.

8. The method of claim 7, further comprising forming the coating on the major surface of the CMC component.

9. The method of claim 1, wherein the plurality of CMC reinforcing pins has an average spacing between 2 to 10 times a diameter of a CMC reinforcing pin in the plurality of CMC reinforcing pins.

10. The method of claim 1, wherein at least one CMC reinforcing pin of the plurality of CMC reinforcing pins has a length between about 0.05 and about 10 mm.

11. The method of claim 1, wherein at least one CMC reinforcing pin of the plurality of CMC reinforcing pins has a diameter between about 0.1 and about 1 mm.

12. The method of claim 1, wherein the ceramic fiber preform and the plurality of CMC reinforcing pins comprise a reinforcement comprising SiC and a matrix material comprising SiC.

13. A ceramic matrix composite (CMC) article comprising:

a CMC substrate defining a major surface; and

a plurality of CMC reinforcing pins at least partially embedded in the CMC substrate, wherein each CMC reinforcing pin of the plurality of CMC reinforcing pins defines a respective long axis, and wherein the respective long axes are oriented at an angle substantially perpendicular to the major surface of the CMC substrate.

14. The CMC article of claim 13, wherein each CMC reinforcing pin of the plurality of CMC reinforcing pins includes ceramic fibers oriented substantially parallel to a lateral surface of each respective CMC reinforcing pin and extends substantially a length of each respective CMC reinforcing pin.

15. The CMC article of claim 13, further comprising a coating on the major surface of the CMC substrate.

16. The CMC article of claim 15, wherein a first section of at least one CMC reinforcing pin in of plurality of CMC reinforcing pins is embedded in the coating, and wherein a second section of the at least one CMC reinforcing pin of the plurality of CMC reinforcing pins is embedded in the CMC substrate.

17. The CMC article of claim 13, wherein the plurality of CMC reinforcing pins has an average spacing between 2 to 10 times a diameter of a CMC reinforcing pin in the plurality of CMC reinforcing pins.

18. The CMC article of claim 13, wherein at least one CMC reinforcing pin of the plurality of CMC reinforcing pins has a length between about 0.05 and about 10 mm.

19. The CMC article of claim 13, wherein at least one CMC reinforcing pin of the plurality of CMC reinforcing pins has a diameter between about 0.1 and about 1 mm.

20. The CMC article of claim 13, wherein the CMC substrate and the plurality of CMC reinforcing pins comprise a reinforcement comprising SiC and a matrix material comprising SiC.