Ceramic matrix composite attachment apparatus and method

• US 8,061,977 B2
• Filed: 07/03/2007
• Issued: 11/22/2011
• Est. Priority Date: 07/03/2007
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Energy Incorporated (Siemens AG)
• Inventors: Morrison, Jay A., Keller, Douglas A.
• Primary Examiner(s): Look; Edward
• Assistant Examiner(s): Eastman; Aaron R
• Application Number:
  US11/824,796
• Publication Number:
  US 20090010755A1
• Time in Patent Office: 1,603 Days
• Field of Search: 415/173.1, 415/213.1, 415/214.1
• US Class Current: 415/173.1
• CPC Class Codes: F01D 21/045 special arrangements in stators or in rotors dealing with breaking-off of part of rotor
• CPC Class Codes: F01D 25/243 Flange connections; Bolting arrangements F01D25/265 takes precedence
• CPC Class Codes: F01D 25/246 Fastening of diaphragms or stator-rings
• CPC Class Codes: F05D 2300/21 Oxide ceramics
• CPC Class Codes: F05D 2300/603 Composites; e.g. fibre-reinforced

Abstract

An attachment method and flange for connecting a ceramic matrix composite (CMC) component, such as a gas turbine shroud ring (36, 68), to a metal support structure. A CMC flange (20A) may be formed by attaching a wedge-shaped block (26) of a ceramic material to a CMC wall structure (22), and wrapping CMC layers (24) of the wall structure (22) at least partly around the block (26), forming the flange (20A) with an inner oblique face (34) and an outer face (35) normal to the wall structure. An adjacent support structure, such as a metal support ring (40A), may abut the outer face (35) of the CMC flange (20A) and be clamped or bolted to the CMC flange (20A).

Claims

1. An attachment apparatus comprising:

a ceramic matrix composite (CMC) wall structure comprising a layer of CMC fabric impregnated with a ceramic matrix;

a block of additional ceramic material without holes attached to the CMC wall structure, the block comprising a generally wedge-shaped portion; and

the layer of CMC fabric wrapped at least partly around the block of additional ceramic material and bonded thereto, forming an attachment flange with a core of the additional ceramic material;

wherein the block is attached along at least a portion of a peripheral edge of the CMC wall structure, the block comprises an oblique surface proximal to a geometric center of the CMC wall structure, and the attachment flange comprises an outer or distal face.

2. The apparatus claim 1 wherein the CMC fabric is formed continuously around the block of additional ceramic material.

3. The apparatus of claim 1 wherein the CMC wall structure forms a generally cylindrical portion of a gas turbine component, and the attachment flange is clamped to an adjacent hoop-shaped support structure.

4. The apparatus of claim 1 wherein the layer of CMC fabric covering the oblique surface of the block forms a first contact face for a circular V-band attachment, and a matching flange on an adjacent component comprises a second contact face for the V-band attachment;

wherein the second contact face is symmetric with the first contact face about the distal face of the attachment flange.

5. The apparatus of claim 1 wherein the layer of CMC fabric covering the inner oblique surface of the block forms a contact face for a circular clamp plate, the clamp plate is attached to an adjacent component that abuts the outer face of the attachment flange, the clamp plate spans to a second edge of the CMC wall structure opposite said peripheral edge, and the clamp plate is attached to a second adjacent component abutting said second edge.

6. The apparatus of claim 1 wherein the CMC fabric is formed discontinuously around the block of additional ceramic material.

7. A method for attaching a ceramic matrix composite (CMC) component to an adjacent structure, comprising:

forming a CMC wall structure comprising a layer of CMC fabric impregnated with a ceramic matrix;

attaching a block of additional ceramic material to the CMC wall structure, the block comprising a generally wedge-shaped portion; and

wrapping the layer of CMC fabric at least partly around the block of additional ceramic material, thus forming an attachment flange with a core of the additional ceramic material;

wherein the block is attached along at least a portion of a peripheral edge of the CMC wall structure, the block comprises a surface that is oblique relative to the CMC wall structure and is proximal to a geometric center of the CMC wall structure, and the attachment flange comprises an outer or distal face substantially normal to the CMC wall structure;

wherein the layer of CMC fabric covering the oblique surface of the block forms a first contact face for a circular V-band attachment, and a matching flange on an adjacent component comprises a second contact face for the V-band attachment;

wherein the second contact face is symmetric with the first contact face about the distal face of the attachment flange.

8. The attachment method of claim 7 wherein the CMC fabric is formed continuously around the block of additional ceramic material.

9. The attachment method of claim 7 wherein the CMC wall structure forms a generally cylindrical portion of a gas turbine component, and the attachment flange is clamped to an adjacent hoop-shaped support structure.

10. The attachment method of claim 7 wherein the layer of CMC fabric covering the oblique surface of the block forms a contact face for a circular clamp plate, the clamp plate is attached to an adjacent component that abuts the outer face of the attachment flange, the clamp plate spans to a second edge of the CMC wall structure opposite said peripheral edge, and the clamp plate is further attached to a second adjacent component abutting said second edge.

11. The attachment method of claim 7 wherein an access port is formed into the block, the access port comprises an inner face substantially parallel to the outer face of the attachment flange, a clamp bracket is attached to an adjacent component that abuts the outer face of the attachment flange, and a hook on the clamp bracket contacts the inner face of the access port in the block.

12. The attachment method of claim 7 wherein an access port is formed into the block, the access port comprises an inner face substantially parallel to the outer face of the attachment flange, and further comprising a hole between the inner face of the access port and the outer face of the attachment flange for admitting a fastener spanning between the inner face of the access port and an adjacent component that abuts the outer face of the attachment flange.

13. The attachment method of claim 7 wherein the CMC fabric is formed discontinuously around the block of additional ceramic material.

14. An attachment apparatus comprising:

a ceramic matrix composite (CMC) wall structure without holes, comprising a layer of CMC fabric impregnated with a ceramic matrix;

a block of additional ceramic material attached to the CMC wall structure, the block comprising a generally wedge-shaped portion;

the layer of CMC fabric wrapped at least partly around the block of additional ceramic material and bonded thereto, forming an attachment flange with a core of the additional ceramic material;

wherein the CMC wall structure forms a generally cylindrical ring;

wherein the attachment flange is formed at an axially intermediate position on a radially outer surface of the CMC wall structure;

wherein the block of additional ceramic material comprises first and second symmetrically opposed generally wedge-shaped portions; and

wherein a circular metal V-band is clamped around the attachment flange, thus attaching the metal V-band to the CMC wall structure.