Hybrid monolithic ceramic and ceramic matrix composite airfoil and method for making the same

• US 6,696,144 B2
• Filed: 04/24/2002
• Issued: 02/24/2004
• Est. Priority Date: 11/19/1999
• Status: Expired due to Term

• Current Assignee: Raytheon Technologies Corporation d/b/a RTX (Rtx Corporation)
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Sabnis, Jayant S., Holowczak, John E., Tredway, William K., Prewo, Karl M.
• Primary Examiner(s): DIXON, MERRICK L
• Application Number:
  US10/131,403
• Publication Number:
  US 20020155269A1
• Time in Patent Office: 671 Days
• Field of Search: 428/325, 428/241, 428/242, 428/246, 428/312.2, 428/283, 428/294, 428/324, 428/330, 428/331, 428/688, 428/293.4, 501/88, 501/92, 501/95.1, 501/102
• US Class Current: 428/293.4
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: C04B 2235/6562 Heating rate
• CPC Class Codes: C04B 2235/6587 Influencing the atmosphere by vaporising a solid material, e.g. by using a burying of sacrificial powder
• CPC Class Codes: C04B 2237/341 Silica or silicates
• CPC Class Codes: C04B 2237/348 Zirconia, hafnia, zirconates or hafnates
• CPC Class Codes: C04B 2237/365 Silicon carbide
• CPC Class Codes: C04B 2237/368 Silicon nitride
• CPC Class Codes: C04B 2237/385 Carbon or carbon composite
• CPC Class Codes: C04B 2237/565 made of refractory metal oxides, e.g. zirconia
• CPC Class Codes: C04B 35/18 rich in aluminium oxide
• CPC Class Codes: C04B 35/597 based on silicon oxynitride, e.g. SIALONS
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: F01D 5/147 Construction, i.e. structural features, e.g. of weight-saving hollow blades F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F01D 5/284 Selection of ceramic materials
• CPC Class Codes: F01D 5/288 Protective coatings for blades
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/249928 Fiber embedded in a ceramic, glass, or carbon matrix
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 428/249967 : Inorganic matrix in void-containing component
• CPC Class Codes: Y10T 428/252 : Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/259 : Silicic material

Abstract

The present invention is a low density hybrid airfoil comprising a temperature resistant exterior layer and a tough, high impact resistant interior layer. Specifically, the airfoil comprises a monolithic ceramic exterior layer and a fiber reinforced ceramic matrix composite interior layer. Both the monolithic ceramic and fiber reinforced ceramic matrix composite are low density materials. Additionally, the monolithic ceramic is a high temperature resistant material, and the fiber reinforced ceramic matrix composite is a relatively high impact resistant structure. Encapsulating the airfoil with a temperature resistant exterior layer protects the airfoil in a high temperature environment, and supporting the airfoil with a high impact resistant, fiber reinforced ceramic matrix composite improves the overall impact resistance of the airfoil thereby resulting in a tough, high temperature resistant, low density airfoil.

Claims

1. An airfoil, comprising:

(a) a first layer comprising a monolithic ceramic; and

(b) a second layer comprising a fiber reinforced ceramic matrix composite, said second layer being interior to said first layer.

2. The airfoil of claim 1 wherein said monolithic ceramic contacts said fiber reinforced ceramic matrix composite.

3. The airfoil of claim 2 wherein said monolithic ceramic is affixed to said fiber reinforced ceramic matrix composite.

4. The airfoil of claim 1 wherein said monolithic ceramic is selected from the group consisting essentially of silicon nitride (Si₃N₄), silicon aluminum oxynitride (SiAlON), silicon oxynitride (Si₂N₂O), silicon carbide (SiC), aluminum nitride (AlN), aluminum oxide (Al₂O₃), hafnium oxide (HfO₂), zirconia (ZrO₂) siliconized silicon carbide (SiSiC) and combinations thereof.

5. The airfoil of claim 1 wherein said fiber reinforced ceramic matrix composite is a glass-ceramic matrix composite.

6. The airfoil of claim 5 wherein said fiber reinforced glass-ceramic matrix composite comprises a matrix selected from the group consisting essentially of magnesium aluminum silicate, magnesium barium aluminum silicate, lithium aluminum silicate, barium strontium aluminum silicate, barium aluminum silicate and combinations thereof.

7. The airfoil of claim 6 wherein said glass-ceramic matrix composite comprises fibers selected from the group consisting essentially of silicon carbide (SiC), aluminum oxide (Al₂O₃), silicon nitride (Si₃N₄), carbon (C) and combinations thereof.

8. The airfoil of claim 1 wherein said fiber reinforced ceramic matrix composite is formed by a chemical vapor infiltration process.

9. The airfoil of claim 8 wherein said fiber reinforced ceramic matrix composite comprises a matrix selected from the group consisting essentially of silicon carbide (SiC), silicon nitride. (Si₃N₄), aluminum oxide (Al₂O₃), silicon aluminum oxynitride (SiAlON), aluminum nitride (AlN), zirconium oxide (ZrO₂), zirconium nitride (ZrN), hafnium oxide (HfO₂) and combinations thereof.

10. The airfoil of claim 8 wherein said fiber reinforced ceramic matrix composite comprises fibers selected from the group consisting essentially of silicon carbide (SiC), aluminum oxide (Al₂O₃) silicon nitride (Si₃N₄), Carbon (C) and combinations thereof.

11. The airfoil of claim 1 wherein said fiber reinforced ceramic matrix composite is formed by a pre ceramic polymer infiltration pyrolysis process.

12. The airfoil of claim 11 wherein said fiber reinforced ceramic matrix composite comprises a matrix selected from the group consisting essentially of silicon nitride carbon oxygen compound (Si—

N—

C—

O), boron nitride (BN), silicon carbide (SiC) and silicon nitride (Si₃N₄).

13. The airfoil of claim 11 wherein said fiber reinforced ceramic matrix composite comprises fibers selected from the group consisting essentially of silicon carbide (SiC), aluminum oxide (Al₂O₃) and combinations thereof.