Process for producing ceramic composite components

Abstract

A process for producing components containing ceramic materials. The process entails forming a first region of a component with plies containing a reinforcement material in a precursor of a ceramic material. The plies include at least a first set of plies between at least second and third sets of plies. Distal portions of the second and third sets of plies are then folded away from the first set of plies so that they are oriented transverse to the first set of plies. A fourth set of plies is then interleaved among the folded distal portions of the second and third sets of plies.

Description

Background technique [0001] This application claims the benefit of US Provisional Application No. 61 / 615,074, filed March 23, 2012, the contents of which are hereby incorporated by reference. [0002] The present invention generally relates to ceramic-based articles and methods for their production. More specifically, the present invention relates to methods for producing ceramic matrix composite (CMC) components having detailed features, such as tip shrouds for turbine airfoil components. [0003] In order to increase the efficiency of gas turbines, higher operating temperatures for the gas turbines are continuously sought. Although advances in nickel-based superalloys have allowed turbines to operate at these higher temperatures, there is a step change in performance among alternative materials currently being investigated. Ceramic materials are a notable example because their high temperature performance can significantly reduce cooling air requirements. As used herein, ...

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Problems solved by technology

However, the tip shroud 20 (together with the dovetail 12 and platform 14) represents the detailed geometry of the blade 10, which is critical to the design, manufacture and integration of CMC components into affordable, producible components for turbine applications. The structure of the

for example, the use of CMC materials to integrate the tip shroud 20 with the airfoil 16 creates complexities in the design and manufacturing process and results in an approach that may be too expensive to be economically viable

In addition, the low strain failure capability of typical CMC materials presents additional challenges regarding the use of CMC materials in shrouded blade designs

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