Composite component with additive printed inner portion

Abstract

A composite component for a gas turbine engine and a method of forming the same are provided. The composite component includes: an additively printed inner portion defining at least one flow path feature; and a ceramic matrix composite (CMC) outer portion formed on the additive printed inner portion such that the CMC outer portion substantially surrounds the additive printed inner portion. The inner part of the additive printing comprises SiC; and the CMC outer portion includes a fiber reinforced ceramic matrix (e.g., including SiC) and defines at least one cooling cavity fluidly coupled to the at least one flow path feature of the additive printed inner portion.

Description

Technical Field

[0001] The present disclosure relates to composite parts including additively printed interior components. Background Art

[0002] Reinforced ceramic matrix composites ("CMCs") composed of fibers dispersed in a continuous ceramic matrix of the same or different composition are well suited for structural applications due to their toughness, heat resistance, high temperature strength, and chemical stability. Such composites typically have a high strength-to-weight ratio, which makes them attractive in weight-conscious applications, such as in aerospace applications. Their stability at high temperatures makes CMCs well suited for applications where the component is in contact with hot gases, such as in gas turbine engines. However, ceramic fibers used to form fiber-reinforced CMC materials can be expensive. Additionally, cooling fiber-reinforced composites can be difficult. Therefore, improved components that address one or more of these challenges would be desirable. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] A full and enabling disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0004] Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary aspect of the present disclosure;

[0005] Figure 2A is a perspective view of a composite airfoil having an additively printed interior portion according to an exemplary aspect of the present disclosure;

[0006] Figure 2B yes Figure 2A A three-dimensional image of the additively printed interior of the

[0007] Figure 3 is a schematic cross-sectional view of a composite airfoil having an additively printed interior portion positioned in a trailing edge region of the composite airfoil according to an exemplary aspect of the present disclosure;

[0008] Figure 4 is a schematic cross-sectional view of a composite airfoil having an additively printed internal segment defining an additively printed internal segment cavity according to an exemplary aspect of the present disclosure;

[0009] Figure 5 is a schematic cross-sectional view of a composite airfoil having an additively printed interior portion positioned at or near a leading edge of the composite airfoil according to an exemplary aspect of the present disclosure;

[0010] Figure 6is a schematic cross-sectional view of a composite airfoil having an additively printed internal branch defining an additively printed internal manifold divided into a plurality of chambers according to an exemplary aspect of the present disclosure;

[0011] Figure 7 is a schematic cross-sectional view of a composite airfoil having an additively printed interior portion disposed along a suction side of the composite airfoil according to an exemplary aspect of the present disclosure;

[0012] Fig. 8A is a schematic cross-sectional view of a composite airfoil having an additively printed inner portion defining a serpentine cavity according to an exemplary aspect of the present disclosure;

[0013] Figure 8B yes Figure 8B A schematic cross-sectional view of a composite airfoil of , the cross section being taken along a radial direction;

[0014] Fig. 9 is a schematic cross-sectional view of a composite nozzle airfoil assembly having an additively printed inner portion disposed in an inner band according to an exemplary aspect of the present disclosure;

[0015] Fig.10 is a schematic cross-sectional view of a composite shield having an additively printed interior portion according to an exemplary aspect of the present disclosure;

[0016] Fig.11A is a schematic cross-sectional view of a composite airfoil having an additively printed internal portion defining a cell structure according to an exemplary aspect of the present disclosure;

[0017] Fig. 11B yes Fig.11A A schematic cross-sectional view of a composite airfoil of , the cross section being taken along a radial direction;

[0018] Fig.12 is a schematic cross-sectional view of a composite shroud having an additively printed inner portion used as a mandrel according to an exemplary aspect of the present disclosure; and

[0019] Fig.13 is a flow chart illustrating a method for forming a composite part according to an exemplary aspect of the present disclosure. DETAILED DESCRIPTION

[0020] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. In addition, unless expressly stated otherwise, all embodiments described herein should be considered exemplary.

[0021] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0022] The term "at least one" in a context such as "at least one of A, B, and C" means only A, only B, only C, or any combination of A, B, and C.

[0023] The terms “turbomachine” or “turbomachine” refer to a machine that includes one or more compressors, a heat generating section (eg, a combustion section), and one or more turbines that together generate a torque output.

[0024] The term "gas turbine engine" refers to an engine having a turbine as all or part of its power source. Example gas turbine engines include turbofan engines, turboprop engines, turbojets, turboshaft engines, etc., as well as hybrid-electric versions of one or more of these engines.

[0025] The terms "upstream" and "downstream" refer to relative directions relative to the flow of a fluid in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, and "downstream" refers to the direction toward which the fluid is flowing.

[0026] As used herein, the terms "axial" and "axially" refer to directions and orientations extending substantially parallel to the centerline of the gas turbine engine. Additionally, the terms "radial" and "radially" refer to directions and orientations extending substantially perpendicular to the centerline of the gas turbine engine. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to directions and orientations extending in an arc around the centerline of the gas turbine engine.

[0027] Unless otherwise indicated herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment via one or more intermediate components or features.

[0028] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of each component.

[0029] For the purposes of the description hereinafter, the terms "upper", "lower", "right", "left", "vertical", "horizontal", "top", "bottom", "lateral", "longitudinal" and their derivatives shall relate to the embodiments as they are oriented in the accompanying drawings. However, it should be understood that the embodiments may assume various alternative variations unless expressly indicated to the contrary. It should also be understood that the specific devices shown in the drawings and described in the following specification are merely exemplary embodiments of the present disclosure. Therefore, specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting.

[0030] The term "adjacent" as used herein when referring to two walls and / or surfaces means that the two walls and / or surfaces are in contact with each other, or that the two walls and / or surfaces are separated only by one or more non-structural layers, and the two walls and / or surfaces are in a series contacting relationship with the one or more non-structural layers (i.e., a first wall / surface contacts the one or more non-structural layers, and the one or more non-structural layers contacts the second wall / surface).

[0031] As used herein, the terms "integral," "unitary," or "monolithic" used to describe a structure means that the structure is integrally formed from a continuous material or group of materials without seams, connections, joints, etc. The integral unitary structures described herein may be formed by additive manufacturing to have the structure, or alternatively formed by a layup process, a casting process, etc.

[0032] As used herein, the term "build plane" refers to a plane defined by a surface upon which an energy beam impinges to selectively irradiate and thereby consolidate powdered material during an additive manufacturing process.

[0033] As used herein, the term "consolidation" or "curing" refers to the solidification of a powder material as a result of irradiating the powder material (including by melting, fusing, sintering, etc.).

[0034] As used herein, ceramic matrix composites or "CMCs" refer to a class of materials that include reinforcement materials (e.g., reinforcing fibers) surrounded by a ceramic matrix phase. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of matrix materials for CMCs may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) may also be included in the CMC matrix.

[0035] Some examples of reinforcing fibers for CMCs may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates such as mullite, or mixtures thereof), or mixtures thereof.

[0036] As used herein, the terms "substantially surround" and "substantially surround" mean that at least 90% of the surface area of ​​the inner portion is covered by the CMC outer portion, such as 95% of the surface area of ​​the inner portion is covered by the CMC outer portion. It should be noted that the area defined by any inlet 126 and / or outlet 128 is not included in the surface area of ​​the inner portion 120. The terms "substantially surround" and "substantially surround" can include completely surrounding (e.g., enclosing) and completely surrounding (e.g., wrapping), respectively. The terms "surrounding" and "wrapping" mean completely surrounding the inner portion, but excluding any fluid cavity or channel defined therein.

[0037] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter references to refer to features in the drawings. Like or similar reference numbers in the drawings and description have been used to refer to like or similar parts of the present disclosure.

[0038] In general, specific CMCs can be referred to as their fiber type / matrix type combination. For example, C / SiC is carbon fiber reinforced silicon carbide, SiC / SiC is silicon carbide fiber reinforced silicon carbide, SiC / SiN is silicon carbide fiber reinforced silicon nitride, SiC / SiC-SiN is silicon carbide fiber-reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, CMCs can be composed of a matrix and reinforcing fibers comprising oxide-based materials such as aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof. Aluminosilicates can include crystalline materials such as mullite (3Al2O3·2SiO2), as well as glassy aluminosilicates.

[0039] In certain embodiments, the reinforcing fibers may be bundled and / or coated before being included in the matrix. For example, the fiber bundles may be formed into reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be stacked together to form a preform component. The fiber bundles may be impregnated with the slurry composition before or after forming the preform. The preform may then undergo a thermal treatment (such as curing or burnout) to produce a high coke residue in the preform, and subsequently undergo a chemical treatment (such as melt infiltration with silicon) to obtain a component formed of a CMC material having a desired chemical composition.

[0040] Such materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcement materials), are particularly useful for higher temperature applications. In addition, these ceramic materials are lightweight compared to superalloys, yet still provide strength and durability to components made therefrom. As a result, such materials are currently being considered for use in many gas turbine components used in the higher temperature sections of gas turbine engines (such as airfoils (e.g., turbines and buckets), combustors, shrouds, and other components) that would benefit from the lighter weight and higher temperature capabilities that these materials can provide.

[0041] As described herein, the subject matter of the present disclosure relates to the use of additive manufacturing machines or systems. As used herein, the term "additive manufacturing" generally refers to a manufacturing technique that manufactures parts in a layer-by-layer manner. An exemplary additive manufacturing machine can be configured to utilize any suitable additive manufacturing technology. The additive manufacturing machine can utilize additive manufacturing techniques including powder bed fusion (PBF) technology, such as direct metal laser melting (DMLM) technology, selective laser melting (SLM) technology, directional metal laser sintering (DMLS) technology, or selective laser sintering (SLS) technology. In the exemplary PBF technology, thin layers of powdered material are sequentially applied to a build plane and then selectively melted or fused to each other in a layer-by-layer manner to form one or more three-dimensional objects. Additively manufactured objects are typically integral in nature and can have various integrated sub-components.

[0042] Additionally or alternatively, suitable additive manufacturing techniques may include, for example, fused deposition modeling (FDM) techniques, direct energy deposition (DED) techniques, laser engineered net shaping (LENS) techniques, laser net shaping manufacturing (LNSM) techniques, direct metal deposition (DMD) techniques, digital light processing (DLP) techniques, binder jet printing, and other additive manufacturing techniques that utilize energy beams or other energy sources to solidify additive manufacturing materials (such as powder materials). In fact, any suitable additive manufacturing mode can be used for the subject matter currently disclosed.

[0043] Additive manufacturing techniques can generally be described as making objects by building objects point by point, line by line, or layer by layer, typically in a vertical direction. Other methods of making are also contemplated and within the scope of the present disclosure. For example, although the discussion herein relates to adding materials to form successive layers, the subject matter of the present disclosure can be practiced with any additive manufacturing technique or other manufacturing technique, including layer-additive, layer-subtractive, or hybrid processes.

[0044] The additive manufacturing processes described herein can be used to form parts using any suitable material. For example, the material can be a metal, a ceramic, a polymer, an epoxy resin, a photopolymer resin, a plastic, or any other suitable material that can be a solid, a powder, a sheet, a wire, or any other suitable form, or a combination thereof. Additionally or alternatively, exemplary materials may include metals, ceramics, or adhesives, and combinations thereof. Exemplary ceramics may include ultra-high temperature ceramics and / or precursors to ultra-high temperature ceramics, such as polymer precursors. For example, each successive layer may be between approximately 10 μm and 200 μm, although the thickness may be determined based on any number of parameters and may be of any suitable size.

[0045] Typically, the surface of the powder bed defines a build plane. During irradiation of a respective layer of the powder bed, a previously irradiated portion of the respective layer may define a portion of the build plane. Prior to distributing the powder material on the building blocks, a build plate supporting the powder bed typically defines the build plane.

[0046] The present disclosure generally relates to additively printed internal components of composite parts for defining one or more channels, such as cooling channels, in the composite parts. For example, the additively printed internal components of the composite parts can define one or more channels, and then the additively printed internal components can be wrapped in a composite material or disposed within a composite material to form a composite part. The additively printed internal components defining one or more channels can be formed by additive manufacturing processes, etc., to define complex features or geometries that are difficult or impossible to form in a composite part using traditional techniques (such as laser machining, electrical discharge machining (EDM), etc.). As an example, the present subject matter allows cooling features for improved airfoil cooling, such as improving cooling of the trailing edge region of the airfoil by introducing channels that are closer to the trailing edge of the airfoil and increase the heat transfer coefficient of the cold side or suction side, while avoiding performance losses caused by film cooling the suction side. Thus, the additively printed interior components described herein can improve cooling of a composite component, for example by defining channels for a cooling fluid to provide targeted cooling to specific features or locations within or on the composite component, and / or increasing the heat transfer coefficient at one or more locations of the composite component, or otherwise allowing more efficient heat transfer.

[0047] Referring now to the drawings, in which like numerals refer to like elements throughout, Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary aspect of the present disclosure. More specifically, Figure 1 In the embodiment of the present invention, the gas turbine engine is a high bypass turbofan jet engine 10, referred to herein as a "turbofan engine 10". Figure 1 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to a longitudinal centerline 12 for reference), a circumferential direction C (extending about the longitudinal centerline 12 and the axial direction A), and a radial direction R. Generally, the turbofan engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream of the fan section 14 .

[0048] The depicted exemplary core turbine engine 16 generally includes a substantially tubular casing 18 defining an annular inlet 20. The casing 18 encloses, in serial flow relationship: a compressor section including a supercharger or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and an ejection exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22.

[0049] For the depicted embodiment, fan section 14 includes a fan 38 having a plurality of fan blades 40 coupled in a spaced-apart manner to a hub or disk 42. As depicted, fan blades 40 extend outwardly from disk 42 generally in a radial direction R. Fan blades 40 and disk 42 may rotate together about longitudinal centerline 12 via LP shaft or spool 36. In some embodiments, a power gearbox having a plurality of gears may be included for reducing the rotational speed of LP shaft or spool 36 to a more efficient rotating fan speed.

[0050] Still reference Figure 1 In an exemplary embodiment of the present invention, the disk 42 is covered by a rotatable forward nacelle 48, which is aerodynamically shaped to facilitate airflow through the plurality of fan blades 40. In addition, the exemplary fan section 14 includes an annular fan case or outer nacelle 50 that circumferentially surrounds the fan 38 and / or at least a portion of the core turbine engine 16. It should be understood that the fan case (nacelle) 50 can be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced outlet guide vanes 52. In addition, a downstream section 54 of the fan case 50 can extend over an outer portion of the core turbine engine 16 so as to define a bypass airflow passage 56 therebetween.

[0051] During operation of the turbofan engine 10, a certain amount of air 58 enters the turbofan engine 10 through the fan case 50 and / or the associated inlet 60 of the fan section 14. As the certain amount of air 58 passes through the fan blades 40, a first portion of the air 58, as indicated by arrow 62, is directed or directed into the bypass airflow passage 56, and a second portion of the air 58, as indicated by arrow 64, is directed or directed into the LP compressor 22. The ratio between the first portion of air 62 and the second portion of air 64 is generally referred to as the bypass ratio. The pressure of the second portion of air 64 is then increased as the second portion of air 64 is directed through the compressor section and into the combustion section 26, where the second portion of air 64 is mixed with fuel and combusted to provide combustion gases 66. More specifically, the compressor section includes an LP compressor 22 and an HP compressor 24, each of which may include a plurality of compressor stages 80, wherein each stage 80 includes an annular array or circumferential row of stationary compressor blades 82 (also referred to as compressor stator blades 82) and an annular array or circumferential row of rotating compressor blades 84 (also referred to as compressor rotor blades 84) positioned immediately downstream of the compressor stator blades 82. The plurality of compressor rotor blades 84 in the LP compressor 22 are coupled to the LP shaft or spool 36, and the plurality of compressor blades in the HP compressor 24 are coupled to the HP shaft or spool 34. The plurality of compressor stator blades 82 in the LP compressor 22 are coupled to a compressor casing, and the plurality of compressor stator blades 82 in the HP compressor 24 are coupled to a compressor casing; at least a portion of the HP compressor stator blades 82 are coupled to a compressor casing 90. In some embodiments, the compressor casing 90 may extend through the LP compressor 22 and the HP compressor 24 and support all of the compressor stator blades 82. In other embodiments, the compressor casing 90 supports only a portion of the compressor stator blades 82, and may support only a portion of the compressor stator blades 82 in the HP compressor 24. As previously described, as the second portion of air 64 passes through sequential stages of compressor stator blades 82 and compressor rotor blades 84, the volume of the air 64 is pressurized, i.e., the pressure of the air 64 is increased prior to combusting with the fuel in the combustion section 26 to form the combustion gases 66.

[0052] The combustion gases 66 are directed through the HP turbine 28, wherein a portion of the thermal and / or kinetic energy from the combustion gases 66 is extracted via sequential stages of HP turbine stator blades 68 coupled to the casing 18 and HP turbine rotor blades 70 coupled to the HP shaft or spool 34, thereby rotating the HP shaft or spool 34 to support operation of the HP compressor 24. The combustion gases 66 are then directed through the LP turbine 30, wherein a second portion of the thermal and kinetic energy is extracted from the combustion gases 66 via sequential stages of LP turbine stator blades 72 coupled to the casing 18 and LP turbine rotor blades 74 coupled to the LP shaft or spool 36, thereby rotating the LP shaft or spool 36 to support operation of the LP compressor 22 and / or rotation of the fan 38.

[0053] The combustion gases 66 are then directed through the jet exhaust nozzle section 32 of the core turbine engine 16 to provide propulsive thrust. At the same time, the pressure of the first portion of air 62 is significantly increased, also providing propulsive thrust, as it is directed through the bypass airflow passage 56 before being discharged from the fan nozzle exhaust section 76 of the turbofan engine 10. The HP turbine 28, the LP turbine 30, and the jet exhaust nozzle section 32 at least partially define a hot gas path 78 for directing the combustion gases 66 through the core turbine engine 16.

[0054] although Figure 1 The gas turbine engine of FIG. 1 is depicted as a turbine shaft configuration, but it should be understood that the teachings of the present disclosure can be applied to other types of turbine engines, more general turbines, and other shaft systems. For example, the turbine engine can be another suitable type of gas turbine engine, such as a turboprop engine, a turbojet engine, a turbofan engine, an aeroderivative engine, etc. The present disclosure can also be applied to other types of turbomachinery, such as a steam turbine engine. In addition, the present disclosure can be applied to other types of composite components, such as those used in applications other than turbomachinery.

[0055] Figure 2A Provided is a method for use with a gas turbine engine such as Figure 1 1 is a perspective view of a composite component 100 (shown as an airfoil) of a turbofan engine 10 shown in FIG. That is, for the embodiments described herein, the composite component 100 is formed of a composite material (eg, a ceramic matrix composite (CMC) material).

[0056] like Figure 2AAs shown, the airfoil 101 includes a concave pressure side 102 opposite to a convex suction side 104. The pressure side 102 is opposite to the suction side 104, and the opposite pressure side 102 and suction side 104 of the airfoil 101 extend along a radial direction R over a span S from an inner end 106 to an outer end 108. The inner end 106 may be, for example, a root of a blade airfoil, and the outer end 108 may be, for example, a tip of a blade airfoil. The pressure side 102 and suction side 104 of the airfoil 101 extend along an axial direction A between a leading edge 110 and a trailing edge 112, i.e., the trailing edge 112 is opposite to the leading edge 110 along the axial direction A. The leading edge 110 defines a front end of the airfoil 101, and the trailing edge 112 defines a rear end of the airfoil 101.

[0057] like Figure 2A As shown, the composite part 100 includes an additively printed inner portion 120 and a CMC outer portion 122 that substantially surrounds the additively printed inner portion 120 . Figure 2B Provided Figure 2A A perspective view of the additively printed interior portion 120 is shown. Figure 2B The additively printed inner portion 120 defines a plurality of cooling channels 124 (serving as the plurality of flow path features 124 ), wherein each cooling channel 124 of the plurality of cooling channels 124 has an inlet 126 and an outlet 128 . The additively printed inner portion 120 also has an outer surface 130 .

[0058] Return to reference Figure 2A , the CMC outer portion 122 substantially surrounds the additively printed inner portion 120, such that the CMC outer portion 122 is in contact with the outer surface 130. In addition, the CMC outer portion 122 has a cover outer surface 132. Figure 2A In the illustrated embodiment, the outlet 128 of each cooling channel 124 extends to the cover outer surface 132, which defines the outer surface of the airfoil 101. That is, the outlet 128 of each cooling channel 124 is defined along the outer surface of the airfoil 101. However, in some embodiments, the outlet 128 of one or more of the cooling channels 124 may be defined at the cover outer surface 132, such that at least one (but not necessarily all) of the outlets 128 are defined at the cover outer surface 132.

[0059] like Figure 2A As shown, in some embodiments, the airfoil 101 defines a cooling cavity 134 for receiving a cooling fluid F, and the trailing edge 112 of the airfoil 101 is defined by a trailing edge region 136 positioned behind the cooling cavity 134. The cooling cavity 134 may be defined by the CMC outer portion 122 or another portion of the composite material. In addition, the cooling cavity 134 may extend in the radial direction R over all or only a portion of the span S between the inner end 106 and the outer end 108. In addition, although Figure 2AThe cooling cavity 134 is shown in FIG. 1 (and other figures) as being defined adjacent the leading edge 110 , but it should be understood that the cooling cavity 134 may be defined at any suitable location along the axial direction A between the leading edge 110 and the trailing edge 112 .

[0060] exist Figure 2A In the embodiment of the present invention, the additively printed inner portion 120 is disposed in the trailing edge region 136 and is positioned adjacent to the suction side 104 such that the additively printed inner portion 120 is closer to the suction side 104 than to the pressure side 102. More generally, a centerline M ( Figure 2B ) may be closer to one of the pressure side 102 or the suction side 104 .

[0061] Positioning the additively printed inner portion 120 closer to one side of the airfoil 101 than the other side of the airfoil 101 may allow for customized or targeted cooling of the airfoil 101. For example, Figure 2A As shown, by arranging the additively printed inner portion 120 adjacent to the suction side 104, the suction side 104 can be cooled by heat transfer with the cooling fluid F flowing through the cooling channels 124 of the additively printed inner portion 120, which can eliminate the need for film cooling of the suction side, thereby eliminating the performance loss associated with such film cooling. Additionally or alternatively, in some embodiments, the additively printed inner portion 120 can be positioned closer to the pressure side 102 than the suction side 104 to provide the required cooling along the axial direction of the pressure side 102.

[0062] In some embodiments, Figure 2A As shown, the inlet 126 of each cooling channel 124 may be fluidly coupled to a cooling cavity 134 of the component 100 such that, for example, a cooling fluid F may flow from the cooling cavity 134 into the cooling channel 124 , where the cooling fluid F exits the respective cooling channel 124 at the outlet 128 of the respective cooling channel 124 . Figure 3 , in other embodiments, the additively printed inner portion 120 may be spaced apart from the cooling cavity 134 such that the inlet 126 of each cooling channel 124 is defined away from the cooling cavity 134 while remaining fluidly coupled together. In such an embodiment, the supply channel 138 extends from the cooling cavity 134 to the inlet 126 of each cooling channel 124 in the plurality of cooling channels 124. Thus, for an additively printed inner portion 120 defining a plurality of cooling channels 124, the airfoil 101 may define a corresponding plurality of supply channels 138 within a respective one of the supply channels 138 extending between the cooling cavity 134 and a respective one of the cooling channels 124 of the additively printed inner portion 120.

[0063] Each supply channel 138 includes a supply channel inlet 140 and a supply channel outlet 142. The supply channel inlet 140 is defined at the cooling cavity 134, and the supply channel outlet 142 is defined at the corresponding cooling channel 124. For example, the supply channel outlet 142 of the corresponding supply channel 138 can extend to the inlet 126 of the corresponding cooling channel 124. In this way, each supply channel 138 defines a passage or channel for the cooling fluid F to flow from the cooling cavity 134 to the inner portion 120 of the additive printing, for example, for Figure 3 In the embodiment of the present invention, the cooling channel 124 flows to the inner portion 120 of the additively printed material. Figure 3 In the embodiment of FIG. 1 , the inner portion 120 is enclosed within the CMC outer portion 122 .

[0064] The one or more supply channels 138 may be defined using conventional techniques. For example, the one or more supply channels 138 may be laser drilled; defined by electrical discharge machining (EDM); formed by using fugitive material that is burned off or otherwise removed during thermal and / or chemical treatment of the composite material; or any other suitable technique or combination of techniques.

[0065] refer to Figure 4 , another embodiment of an additively printed inner portion 120 of a composite component, such as an airfoil 101, is described, wherein the inner portion 120 is enclosed within a CMC outer portion 122. Figure 4 As shown in the schematic cross-sectional view of FIG. 1 , the additively printed inner portion 120 can be positioned behind the cooling cavity 134, and the additively printed inner portion 120 can define a portion along the span S ( Figure 2A ) at least a portion of the additively printed internal sub-cavity 144 extending therefrom. That is, the additively printed internal sub-cavity 120 may define its own cooling cavity (i.e., the additively printed internal sub-cavity 144) for receiving the cooling fluid F, the cooling fluid F flowing along the radial direction R ( Figure 2A ) extends over at least a portion of a span S between the inner end 106 and the outer end 108 of the airfoil 101 .

[0066] like Figure 4 As further shown, at least one supply channel 138 extends from the cooling cavity 134 to the additively printed internal sub-cavity 144. For example, for a respective supply channel 138, a supply channel inlet 140 is defined at the cooling cavity 134, and a supply channel outlet 142 is defined at the additively printed internal sub-cavity 144. Thus, the respective supply channel 138 defines a passage or pathway for the cooling fluid F to flow from the cooling cavity 134 to the additively printed internal sub-cavity 120, for example, for Figure 4 In an embodiment, the additively printed inner portion 120 flows into the additively printed inner portion 144. Figure 4As shown, the inlet 126 of the corresponding cooling channel 124 may be defined at the additively printed internal sub-cavity 144 to allow the cooling fluid F to flow from the additively printed internal sub-cavity 144 through the cooling channel 124 and be ejected from the airfoil 101 through the outlet 128 of the corresponding cooling channel 124 .

[0067] In addition, despite Figure 4 1 is defined at the same radial position as the corresponding cooling channels 124, but it should be understood that the supply channels 138 need not be defined at the same radial position as any cooling channels 124 defined by the additively printed inner portion 120. For example, the number of supply channels 138 defined by the airfoil 101 may be different than the number of cooling channels 124 defined by the additively printed inner portion 120, such that not every supply channel 138 may be radially aligned with a corresponding cooling channel 124. For example, the number of supply channels 138 defined in the airfoil 101 may be less than the number of cooling channels 124 defined in the additively printed inner portion 120, and one or more of the supply channels 138 may be defined at a different radial position than each cooling channel 124. As another example, it may be desirable to vary the shape or geometry of the fluid passage through the airfoil 101 , eg, to optimize heat transfer between the cooling fluid and the composite component, and thus, the radial position of the supply channels 138 may differ from the radial position of each cooling channel 124 .

[0068] As described herein, and as Figure 2A As best shown in FIG. 1 , in at least some embodiments, the outlet 128 of the one or more cooling channels 124 of the additively printed inner portion 120 may be defined at an outer surface of the composite part, such as at the cover outer surface 132 . However, in some embodiments, the CMC outer portion 122 may cover the outlet 128 of the one or more cooling channels 124 . Figure 4 In such an embodiment, the injection channel 146 can be defined from the outer surface of the composite component (e.g., from the cover outer surface 132) to the outlet 128 of the corresponding cooling channel 124 to allow the cooling fluid F to be ejected from the corresponding cooling channel 124 to the external environment of the composite component. It should be understood that although Figure 4 The injection channels 146 are depicted extending from the cooling channels 124 to the cover outer surface 132, but in other embodiments, the injection channels 146 may be provided as shown in FIG. Figure 4 The one or more cooling channels 124 of the additively printed inner sub-cavity 144 shown may extend to the cover outer surface 132 such that an outlet 128 of such cooling channel 124 is defined at the cover outer surface 132, as shown in FIG. Figure 2A In addition, although Figure 4104, but one or more ejection channels 146 may be defined from the cover outer surface 132 to the additively printed internal sub-cavity 144. For example, the cooling fluid F may be provided to the pressure side 102, the suction side 104, or both via one or more ejection channels 146 extending from the additively printed internal sub-cavity 144 and / or the cooling channels 124 to the cover outer surface 132 at the pressure side 102, the suction side 104, or both.

[0069] In other embodiments, the additively printed inner portion 120 may be positioned at other locations on the airfoil 101, i.e., the additively printed inner portion 120 need not be positioned adjacent to the trailing edge 112 of the airfoil 101 (e.g., in the trailing edge region 136). Figure 5 and Figure 6 , the additively printed inner portion 120 can be positioned adjacent to the leading edge 110. As another example, referring to Figure 7 , the additively printed inner portion 120 may be positioned between the leading edge 110 and the trailing edge 112 along the axial direction A. For example, Figure 7 As shown, the additively printed inner chamber 120 can be positioned between the cooling chamber 134 and the additively printed inner chamber 144 along or adjacent to the suction side 104, or between the cooling chamber 134 and the additively printed inner chamber 144 along or adjacent to the pressure side 102. Figure 5 , Figure 6 and Figure 7 In the embodiment of FIG. 1 , the inner portion 120 is enclosed within the CMC outer portion 122 .

[0070] and Figure 5 , Figure 6 and Figure 7Keeping in line, in some embodiments, the cooling channels 124 can be configured as additively printed internal manifolds 148. For example, rather than a plurality of cooling channels 124 forming a passage for a cooling fluid F to flow through the additively printed internal manifolds 120 (e.g., from an inlet 126 to an outlet 128 of each cooling channel 124), the additively printed internal manifolds 120 can define additively printed internal manifolds 148. One or more supply channels 138 can deliver the cooling fluid F from the cooling cavity 134 to the additively printed internal manifolds 148, and one or more ejection channels 146 can deliver the cooling fluid F from the additively printed internal manifolds 148 to an environment outside the cover outer surface 132 or the composite part (airfoil 101). Each supply channel 138 can extend from a supply channel inlet 140 defined at the cooling cavity 134 to a supply channel outlet 142 at the additively printed internal manifold 148. Each jet channel 146 may extend from a jet channel inlet 150 defined at the additively printed internal manifold 148 to a jet channel outlet 152 defined at the cover outer surface 132 .

[0071] The additively printed internal branch pipe 148 can be in the span S( Figure 2A ) along the radial direction R( Figure 2A ). For example, the additively printed internal branch pipe 148 may have a depth perpendicular to a length l defined between an inlet 126 of a cooling channel 124 defined at a radial position and an outlet 128 of the cooling channel 124 defined at the same radial position, such as Figure 5 As shown, Figure 5 is along the plane along the span S( Figure 2A ) position. In some embodiments, the plurality of supply channels 138 may be defined at two or more radial positions, and / or the plurality of injection channels 146 may be defined at two or more radial positions to provide a plurality of injection channels 146 along the span S ( Figure 2A ) at different locations of the internal branch pipe 148 of the additive printing and / or the cooling fluid F is transported and / or delivered to the internal branch pipe 148 of the additive printing and / or the cooling fluid F is transported and / or delivered from the internal branch pipe 148 of the additive printing.

[0072] Special References Figure 6 , the additively printed internal branch pipe 148 can be divided into a plurality of chambers 154, wherein ribs 156 are disposed between adjacent chambers 154 to separate the chambers 154. In some embodiments, the additively printed internal branch pipe 148 can be divided into two or more chambers 154, each chamber 154 extending radially, that is, similar to the additively printed internal branch pipe 148, each chamber 54 has a span S( Figure 2A), so that each chamber 154 has a depth. In other embodiments, the additively printed internal branch tube 148 can be divided into two or more chambers 154, each chamber 154 extending generally along the axial direction A, that is, the first chamber 154 can extend along the radial direction R over a first portion of the span S, and the second chamber 154 can extend along the radial direction R over a second portion of the span S, so that the first chamber 154 and the second chamber 154 are defined at different radial positions, rather than being defined at different axial positions and / or circumferential positions.

[0073] Go to Figure 7 , the injection channel 146 can be separated from the supply channel 138, for example, to optimize thermal design. For example, a non-linear path can be defined from the supply channel inlet 140 to the injection channel outlet 152. As an example, in Figure 7 In the embodiment of the present invention, a supply channel 138 is defined in the airfoil 101 to supply a cooling fluid F to the additively printed inner portion 120, and an ejection channel 146 is defined in the airfoil 101 to direct the cooling fluid F to the cover outer surface 132 of the airfoil 101, or to the environment outside the airfoil 101. Figure 7 The supply channel 138 and the jet channel 146 of the airfoil 101 shown in FIG. 1 are defined at the same radial position, but the supply channel 138 and the jet channel 146 are each defined at an angle relative to the additively printed inner portion 120 and relative to the axial direction A. Therefore, the cooling fluid F must flow along a non-linear path from the supply channel inlet 140 to the jet channel outlet 152. For example, in the depicted embodiment, the cooling fluid F must flow generally rearward to enter the additively printed inner portion 120 through the supply channel 138, then flow generally forward to exit the additively printed inner portion 120 through the jet channel 146, and finally flow generally rearward to exit the jet channel 146 and reach the exterior of the airfoil 101.

[0074] Figure 5 and Figure 6 The additively printed inner portion 120, the supply channel 138, and the ejection channel 146 shown in the embodiment of FIG. 1 similarly illustrate a non-linear path from the cooling cavity 134 through the additively printed inner portion 120 to the exterior of the airfoil 101, while Figure 2A , Figure 2B , Figure 3 and Figure 4 The embodiment of FIG. 1 shows a generally linear path of cooling fluid F flowing from the cooling cavity 134 through the additively printed inner portion 120 and to the exterior of the airfoil 101. For example, Figures 5 to 7The non-linear paths depicted in FIG. 1 may increase heat transfer or otherwise provide more beneficial cooling than the linear paths through the depicted additively printed inner portion 120. However, it may be desirable in some areas of a composite part, e.g. Figures 2A to 4 The linear paths shown in FIG. 1 are used to optimize cooling of these areas of the composite component.

[0075] Reference now Fig. 8A and Figure 8B . Fig. 8A The composite component 100 is provided in a direction perpendicular to the span direction (or radial direction R, see Figure 8B ), and Figure 8B A cross-sectional view of the composite component 100 in a plane extending in the radial direction R and between the leading edge 110 and the trailing edge 112 is provided (note that Figure 8B are schematic plan views depicting certain aspects discussed below). Fig. 8A and Figure 8B The composite component 100 may be constructed in a similar manner as one or more of the example composite components described above.

[0076] refer to Fig. 8A and Figure 8B One or more ejection channels 146 may be defined in the additively printed inner chamber 144 for cooling fluid F to flow from the additively printed inner chamber 120 to the cover outer surface 132 of the airfoil 101. For example, Fig. 8A As shown, the plurality of injection channels 146 may be defined at a plurality of axial locations, for example, from one or more portions of the corresponding serpentine passage 164 (see Figure 8B ). In some embodiments, a plurality of injection channels 146 may be defined to specific portions of the serpentine passage 164, such as a first injection channel 146A, a second injection channel 146B, and a third injection channel 146C defined to a first portion 170 of the first serpentine passage 164A at or adjacent to the leading edge 110 (such as in the leading edge region 111). As a further example, reference Figure 8B , multiple injection channels 146 may be defined at approximately the same axial position, but at different radial positions, such as at or adjacent to the trailing edge 112. It should be understood that, as described, for example, with respect to Figure 2B As mentioned, in some embodiments, the additively printed inner portion 120 may extend to the trailing edge 112 and define a plurality of outlets 128 such that the additively printed inner portion 120 , rather than the jet channels 146 , directs the cooling fluid F to the cover outer surface 132 and / or the external environment of the airfoil 101 .

[0077] In one or more of the embodiments discussed above (e.g., FIG. 2A to FIG. 8BIn one or more embodiments of the present invention, the additively printed inner portion 120 is formed of a first material and the CMC outer portion 122 is formed of a second material. However, in some embodiments, one or more properties of the first material and the second material are substantially similar or identical. For example, the first material may be a monolithic ceramic material (i.e., without fibers), and the second material may be a fiber-reinforced ceramic matrix composite (CMC) material, wherein the monolithic ceramic material is the same or substantially similar to the ceramic matrix of the fiber-reinforced CMC material. That is, in various embodiments, the CMC outer portion 122 may be formed of a second material including fibers disposed in a ceramic matrix, and the additively printed inner portion 120 may be formed of a first material including a ceramic matrix. In some embodiments, the ceramic matrix of the additively printed inner portion 120 may be different from the ceramic matrix of the CMC outer portion 122, i.e., the first material may differ from the second material in more than just fiber reinforcement, but in other embodiments, the ceramic matrix of the additively printed inner portion 120 may be the same as the ceramic matrix of the CMC outer portion 122. In any case, one or more properties of the first material forming the additively printed inner portion 120 and the second material forming the CMC outer portion 122 may be the same, such that the additively printed inner portion 120 and the CMC outer portion 122 are formed of compatible materials for bonding, thermal expansion, etc. That is, the first material and the second material may be selected to have one or more common properties to provide adequate bonding between the additively printed inner portion 120 and the CMC outer portion 122 to avoid component failure due to mismatched coefficients of thermal expansion, etc.

[0078] The additively printed inner portion 120 can be formed by various methods. For example, the additively printed inner portion 120 can be a ceramic component, such as a silicon carbide (SiC) component, formed by an additive manufacturing process. In some embodiments, the additively printed inner portion 120 can be an additively formed SiC composition or an additively formed SiC monolith. In an exemplary embodiment, the additively printed inner portion 120 is formed using an additive manufacturing process. For example, the additively printed inner portion 120 includes a plurality of layers, which are formed by depositing layers of additive material on a bed of an additive manufacturing machine and selectively directing energy from an energy source to the layers of additive material to melt a portion of the additive material. Through this additive process, the additively printed inner portion can be an integrally formed component, such as a single integral component. Additive manufacturing is described in more detail elsewhere herein.

[0079] Now go to Fig. 9 and Fig.10 , provides views of composite components according to two additional embodiments, showing that the composite component need not be such as Figure 2A The airfoil shown may instead be another composite component, such as a turbofan engine 10 ( Figure 1) is another composite component.

[0080] First reference Fig. 9 , depicting a schematic diagram of a composite component. For example, in some embodiments, the composite component may be a nozzle airfoil assembly 100' having at least one of an inner band 174 or an outer band 176. It should be understood that the nozzle airfoil assembly 100' may also include an airfoil 101 extending from at least one of the inner band 174 or the outer band 176, and the airfoil 101 may be constructed as described elsewhere herein.

[0081] and Fig. 9 Consistently, the nozzle airfoil assembly 100' also includes an additively printed inner portion 120' disposed in at least one of the inner band 174 or the outer band 176. Fig. 9 In embodiments, the additively printed inner portion 120' is disposed in the inner band 174; in other embodiments, the additively printed inner portion 120' may be disposed in the outer band 176, or a first additively printed inner portion 120' may be disposed in the inner band 174 and a second additively printed inner portion 120' may be disposed in the outer band 176. The additively printed inner portion 120' defines a cooling channel 124' having an inlet 126' and an outlet 128'. In addition, the nozzle airfoil assembly 100' defines a cooling cavity 134', and the CMC outer portion 122' defines a cover outer surface 132' surrounding (enclosing) the additively printed inner portion 120'. Fig. 9 , the additively printed inner portion 120' is disposed in a rearward portion of the inner band 174, for example, generally adjacent to the trailing edge 112 of the airfoil 101 extending between the inner band 174 and the outer band 176 of the nozzle airfoil assembly 100' as shown. In other embodiments, the additively printed inner portion 120' may be disposed in another region of the inner band 174 (e.g., in a forward portion adjacent to the leading edge 110 of the airfoil 101), or in a forward or rearward portion of the outer band 176.

[0082] In the depicted embodiment, the inlet 126' of the cooling channel 124' is defined at the cooling cavity 134', and the injection channel 146' is defined from the injection channel inlet 150' and the outlet 128' of the cooling channel 124' to the injection channel outlet 152' at the cover outer surface 132'. In other embodiments, the inlet 126' of the cooling channel 124' may be defined at the cooling cavity 134', and the outlet 128' may be defined at the cover outer surface 132'. In still other embodiments, such as described above, a supply channel (not shown) may be defined from a supply channel inlet at the cooling cavity 134' to a supply channel outlet at the inlet 126' of the cooling channel 124', and the injection channel 146' may be defined from the outlet 128' of the cooling channel 124' to the cover outer surface 132', or the outlet 128' may be defined at the cover outer surface 132'.

[0083] It should be understood that other variations and configurations of the additively printed inner portion 120 as described herein may be applied to the additively printed inner portion 120', such that the additively printed inner portion 120' may be configured as described with respect to the additively printed inner portion 120. For example, the cooling channels 124' of the additively printed inner portion 120' may be configured as additively printed inner branch pipes, such as Figures 5 to 7 As another example, the additively printed internal branch pipe 148 may be configured with one or more serpentine passages, such as Fig. 8A and Figure 8B As described above regarding serpentine passage 164.

[0084] refer to Fig.10 , a schematic diagram of another composite component 100" is provided. In the depicted embodiment, the composite component 100 may be a shroud 100". For example, the shroud 100" may be radially positioned with a plurality of blades 178 (such as Figure 1 The shroud 100" includes an additively printed inner portion 120" having an outer surface 130" and defining at least one cooling channel 124" having an inlet 126" and an outlet 128". The shroud 100" also includes a CMC outer portion 122" having a cover outer surface 132" and surrounding the additively printed inner portion 120" such that the CMC outer portion 122" is in contact with the outer surface 130".

[0085] like Fig.10As shown, the additively printed inner portion 120" is disposed in a portion of the shroud 100" closest to the plurality of blades 178. In other embodiments, 120" may be positioned in other areas of the shroud 100", such as in a radially extending portion 180 that may be used to attach the shroud 100" to a shroud hanger assembly. In addition, although in Fig.10 Although depicted as an open shield 100", it should be understood that the subject matter described herein may also be applied to box shields or other shield configurations.

[0086] As described elsewhere herein, the shroud 100" may define a cooling cavity 134" that receives a cooling fluid F. One or more supply channels 138" may be defined from the cooling cavity 134" to the additively printed inner portion 120" to supply the cooling fluid F to the cooling channels 124". Additionally or alternatively, the additively printed inner portion 120" may be positioned within the shroud 100" and the CMC outer portion 122" such that an inlet 126" of the cooling channel 124", or an inlet 126" of one or more cooling channels 124" of the additively printed inner portion 120" defining a plurality of cooling channels 124", is defined at the cooling cavity 134". Furthermore, one or more ejection channels 146" may be defined from the cooling channels 124" to the cover outer surface 132" to direct cooling fluid F from the additively printed inner portion 120" to an environment external to the shroud 100", for example, to provide cooling adjacent to a rear portion of the blade 178. Additionally or alternatively, the additively printed inner portion 120" may be positioned within the shroud 100" and the CMC outer portion 122" such that an outlet 128" of a cooling channel 124", or an outlet 128" of one or more cooling channels 124" of an additively printed inner portion 120" defining a plurality of cooling channels 124", is defined at the cover outer surface 132".

[0087] As with the nozzle airfoil assembly 100', it should be understood that other variations and configurations of the additively printed inner portion 120 as described herein may be applied to the additively printed inner portion 120", such that the additively printed inner portion 120" may be configured as described with respect to the additively printed inner portion 120. For example, the cooling channels 124" of the additively printed inner portion 120" may be configured as an additively printed inner branch pipe, such as Figures 5 to 7 As another example, the additively printed internal branch pipe 148 can be configured with one or more serpentine passages, such as Fig. 8A and Figure 8B As described above regarding serpentine passage 164.

[0088] As shown in the figures, in at least some embodiments, the additively printed inner portion 120 includes a plurality of heat transfer elements 182 extending into at least one cooling channel 124. For example, referring to Figure 3 , the additively printed inner portion 120 includes a plurality of heat transfer elements 182 extending into the depicted cooling channels 124, and with reference to Figure 7 , the additively printed inner branch 120 includes a plurality of heat transfer elements 182 extending into the additively printed inner branch pipe 148 shown. Similarly, Fig. 9 The illustrated additively printed inner portion 120' includes a plurality of heat transfer elements 182' extending into the depicted cooling channels 124' and in Fig.10 In the embodiment, the additively printed internal branch 120" includes a plurality of heat transfer elements 182" extending into the cooling channel 124". The heat transfer elements 182 can, for example, increase heat transfer with the cooling fluid F flowing through the corresponding cooling channel 124 or the additively printed internal branch pipe 148. The heat transfer elements 182 can be configured as pins, fins, turbulators, etc.

[0089] Go to Fig.11A and 11B In some embodiments, the additively printed inner portion 120, 120', 120" may be constructed with a cell structure 184, such as a honeycomb cell structure. The cell structure 184 may, for example, be formed when the cooling fluid F flowing through the additively printed inner portion 120 and the composite component ( Fig.11A and Fig. 11B The unit structures 184 may be oriented differently for different composite components, for example, a nozzle airfoil and a blade may have directional strength differences, or may be oriented differently for composite components at different locations, for example, with respect to the LP turbine 30 ( Figure 1 ) in the nozzle airfoil, the nozzle airfoil immediately adjacent to the combustion section 26 ( Figure 1 ) The nozzle airfoil downstream may have a directional strength difference. The cells 186 of the cell structure 184 can be oriented radially, axially, vertically, horizontally, or in any orientation in a two-dimensional pattern or a three-dimensional pattern. In addition, in some embodiments, the cells 186 can be closed and isolated from each other, and in alternative embodiments, the cells 186 can be open and connected to each other. In other embodiments, the cell structure 184 can be a mixture of open connected cells 186 and closed isolated cells 186, for example, in a portion of the cell structure 184, the cells 186 are open and connected to each other, while in another portion of the cell structure 184, the cells 186 are closed and isolated from each other.

[0090] refer to Fig.12, the additively printed inner portion 120 can be used as a mandrel during the manufacturing process of the resulting composite part 100, and then retained within the part while it is formed. The additively printed inner portion 120 allows for the use of complex mandrel shapes. Thus, after the resulting composite part 100 is consolidated, a non-signature line mandrel can be used without the need for subsequent extraction from the part. Additionally, a plurality of cooling cavities 134 can be defined within the additively printed inner portion 120.

[0091] The outer surface 130 of the additively printed inner portion 120 generally serves as a mandrel for forming the CMC outer portion 122. For example, one or more composite layups may be wrapped around the additively printed inner portion 120 to substantially surround or completely surround the CMC outer portion 122. Although illustrated as including a single additively printed inner portion 120 as a mandrel, it should be understood that any number of additively printed inner portions 120 may be included.

[0092] Reference now Fig.13 , a flow chart of a method 200 for forming a composite part according to an exemplary aspect of the present disclosure is provided. Fig.13 The method 200 may be used to form an exemplary composite component (such as the one described above with reference to FIG. 2A to FIG. 11B Thus, it should be appreciated that the method 200 may generally be used to form a composite component including an additively printed inner portion surrounded by a CMC outer portion. However, in other exemplary aspects, the method 200 may additionally or alternatively be used to form any other suitable composite component.

[0093] As depicted, method 200 includes forming an insert (e.g., an additively printed inner portion) defining at least one cooling channel having an inlet and an outlet at 202. As described herein, the insert may be formed by an additive manufacturing process, but in some embodiments, other processes may also be used. For the additively printed inner portion formed by additive manufacturing, method 200 also includes depositing a layer of additive material on a bed of an additive manufacturing machine at 204, and selectively directing energy from an energy source to the layer of additive material at 206 to melt a portion of the additive material and form the additively printed inner portion. By utilizing such an additive manufacturing process, the additively printed inner portion may be formed with one or more cooling channels as described herein, wherein the one or more cooling channels have any desired location, shape, size, features, etc. For example, when the layer of additive material is deposited on the bed of the additive manufacturing machine, a plurality of heat transfer elements (such as pins, fins, turbulators, etc.) may be formed in the one or more cooling channels, such that when the additive material is melted as described herein, the additively printed inner portion includes at least one cooling channel having a plurality of heat transfer elements formed therein.

[0094] and Fig.13 In keeping with the above, method 200 also includes positioning an insert within the CMC outer portion having the cap outer surface at 208. For example, one or more composite layups may be wrapped around the additively printed inner portion to form the CMC outer portion, or the CMC outer portion may be a composite preform into which the additively printed inner portion is additively printed or positioned. The CMC outer portion may then be formed by chemical vapor infiltration (CVI), melt infiltration (MI), polymer infusion and pyrolysis (PIP) of the preform or multiple layups (e.g., with silicon) surrounding the inner portion.

[0095] As described herein, the CMC outer portion substantially surrounds the insert such that the CMC outer portion is in contact with the outer surface. Also as described herein, a composite component (e.g., a CMC outer portion) may define a cooling cavity for receiving a cooling fluid. In some embodiments, the insert may be disposed within the CMC outer portion such that an inlet of at least one cooling channel is disposed at the cooling cavity to allow cooling fluid to flow from the cooling cavity into the at least one cooling channel. In other embodiments, the CMC outer portion or other material of the composite component is disposed between the insert and the cooling cavity, and the method 200 optionally includes defining one or more supply channels from the cooling cavity to the at least one cooling channel at 210 to provide a channel for cooling fluid to flow from the cooling cavity into the at least one cooling channel. The one or more supply channels may be defined by laser drilling, electrical discharge machining (EDM), or any other suitable process for forming a channel from the cooling cavity to the inner portion of the additive printing.

[0096] Additionally, in some embodiments, the insert may be disposed within the CMC outer portion such that an outlet of the at least one cooling channel extends to the cover outer surface. In other embodiments, the CMC outer portion or other material of the composite component is positioned over the outlet of the at least one cooling channel, or between the inserts at the cover outer surface, and the method 200 optionally includes defining one or more injection channels from the cover outer surface to the at least one cooling channel of the insert at 212 to provide a passage for cooling fluid flowing into the at least one cooling channel to exit the cooling channel and exit the composite component at the cover outer surface. The one or more injection channels may be defined by laser drilling, EDM, or any other suitable process for forming a passage from the cover outer surface to the insert.

[0097] Although the various composite components 100, 100', 100" described and illustrated herein each include an insert (e.g., a single additively printed interior portion 120, 120', 120"), it should be understood that in some embodiments, the composite components 100, 100', 100" may include multiple inserts (e.g., additively printed interior portions 120, 120', 120"). For example, where the composite component is an airfoil 101, the airfoil 101 may include a first additively printed interior portion 120 in the trailing edge region 136 of the airfoil 101 and a second additively printed interior portion 120 positioned near the leading edge 110 of the airfoil 101. Thus, the composite components 100, 100', 100" may include one, two, three, or more separate additively printed interior portions 120, 120', 120". Each additively printed interior portion 120 , 120 ′, 120 ″ may be positioned at or near a location in the respective composite component 100 , 100 ′, 100 ″ where cooling is desired.

[0098] Further aspects are provided by the subject matter of the following clauses:

[0099] A composite component for a gas turbine engine, the composite component comprising: an additively printed inner portion, the additively printed inner portion defining at least one flow path feature, wherein the additively printed inner portion comprises SiC; a ceramic matrix composite (CMC) outer portion, the CMC outer portion formed on the additively printed inner portion such that the CMC outer portion substantially surrounds the additively printed inner portion, wherein the CMC outer portion comprises a fiber reinforced ceramic matrix and defines at least one cooling cavity, the at least one cooling cavity being fluidly coupled to the at least one flow path feature of the additively printed inner portion, wherein the fiber reinforced ceramic matrix comprises SiC.

[0100] A composite part as in any preceding clause, wherein the at least one flow path feature of the additively printed interior portion has a non-linear geometry.

[0101] A composite component as in any preceding clause, wherein the CMC outer portion defines a linear channel fluidly coupling the at least one flow path feature and the at least one cooling cavity.

[0102] A composite component as in any preceding clause, wherein the CMC outer portion defines a hollow airfoil having a cooling cavity therein, and wherein the at least one flow path feature extends non-linearly from the cooling cavity to an exterior surface of the hollow airfoil.

[0103] A composite component according to any preceding clause, wherein the hollow airfoil has a pressure side opposite a suction side and a leading edge opposite a trailing edge, the pressure side and the suction side extending in an axial direction between the leading edge and the trailing edge in a non-linear curved geometry and extending in a radial direction across a span, wherein the cooling cavity is positioned adjacent to the leading edge, and wherein at least one first flow path feature comprises a plurality of cooling channels spaced apart along the span, each cooling channel extending from an inlet in the cooling cavity adjacent to the suction side to an outlet at the trailing edge in a non-linear curved geometry along the axial direction conforming to the non-linear curved geometry of the suction side.

[0104] A composite component as in any preceding clause, wherein the at least one first flow path feature is a cooling channel having a primary flow direction and an interior surface defined by a plurality of heat transfer elements extending into the cooling channel non-parallel to the primary flow direction.

[0105] A composite part as in any preceding clause, wherein the CMC outer portion defines an airfoil and the additively printed inner portion is positioned in a trailing edge region of the airfoil.

[0106] A composite part as in any preceding clause, wherein the CMC outer portion defines an airfoil and the additively printed inner portion is positioned in a leading edge region of the airfoil.

[0107] A composite part as recited in any preceding clause, wherein the CMC outer portion defines an airfoil and the additively printed inner portion is positioned adjacent a suction side of the airfoil.

[0108] A composite part as in any preceding clause, wherein the CMC outer portion defines a nozzle airfoil assembly including an inner band and an outer band, and wherein the additively printed inner portion is positioned in at least one of the inner band or the outer band.

[0109] A composite part as in any preceding clause, wherein the CMC outer portion defines a shroud including an outer surface radially positioned adjacent a plurality of rotatable blades, and wherein the additively printed inner portion is positioned adjacent the outer surface.

[0110] A composite part as in any preceding clause wherein the CMC outer portion is formed by chemical vapor infiltration of a preform or a plurality of plies laminated onto the additively printed inner portion.

[0111] A composite part as in any preceding clause wherein the CMC outer portion is formed by melt infiltration of a preform or a plurality of plies laminated onto the additively printed inner portion.

[0112] A composite part as in any preceding clause wherein the CMC outer portion surrounds the additively printed inner portion.

[0113] A composite component for a gas turbine engine, comprising: an additively printed inner portion, the additively printed inner portion defining at least one cooling channel having an inlet and an outlet, the additively printed inner portion having an outer surface; a ceramic matrix composite (CMC) outer portion, the CMC outer portion substantially surrounding the additively printed inner portion such that the CMC outer portion is in contact with the outer surface, the CMC outer portion having a cap outer surface, wherein the outlet of the at least one cooling channel extends to the cap outer surface.

[0114] A composite component as in any preceding clause, wherein the CMC outer portion defines a hollow airfoil having a cooling cavity therein, and wherein the at least one first flow path feature extends from the cooling cavity to the cover outer surface of the CMC outer portion.

[0115] A composite part as in any preceding clause, wherein the additively printed inner portion comprises SiC, and wherein the CMC outer portion comprises a fiber reinforced ceramic matrix, and wherein the ceramic matrix comprises SiC.

[0116] A composite component as in any preceding clause, wherein the CMC outer portion defines a hollow airfoil, wherein the at least one flow path feature comprises the cooling cavity, and wherein the at least one first flow path feature extends non-linearly from the cooling cavity to an exterior surface of the hollow airfoil.

[0117] A composite component according to any preceding clause, wherein the hollow airfoil has a pressure side opposite a suction side and a leading edge opposite a trailing edge, the pressure side and the suction side extending in an axial direction between the leading edge and the trailing edge in a non-linear curved geometry and extending in a radial direction across a span, wherein the at least one cooling channel is positioned adjacent to the leading edge, and wherein the at least one first flow path feature comprises a plurality of cooling channels spaced apart along the span, each cooling channel extending from an inlet in the at least one cooling channel adjacent to the suction side to an outlet at the trailing edge in a non-linear curved geometry along the axial direction conforming to the non-linear curved geometry of the suction side.

[0118] A composite component according to any preceding clause, wherein the additively printed inner portion comprises a plurality of layers formed by: depositing layers of additive material on a bed of an additive manufacturing machine; and selectively directing energy from an energy source to the layers of additive material to melt a portion of the additive material, wherein the additively printed inner portion is integrally formed as a single, unitary component.

[0119] A composite component comprises: an insert defining at least one cooling channel having an inlet and an outlet, the insert having an insert outer surface; a composite cover surrounding the insert so that the composite cover is in contact with the insert outer surface, the composite cover having a cover outer surface, wherein the outlet of the at least one cooling channel extends to the cover outer surface.

[0120] A composite component as claimed in any preceding clause, wherein the insert is formed from a first material, wherein the composite cover is formed from a second material, and wherein one or more properties of the first material and the second material are the same.

[0121] A composite component as claimed in any preceding clause, wherein the first material is a bulk ceramic material and the second material is a fibre reinforced ceramic matrix composite material.

[0122] A composite component according to any preceding clause, wherein the composite component is an airfoil having a pressure side opposite a suction side and a leading edge opposite a trailing edge, the pressure side and the suction side extending in an axial direction between the leading edge and the trailing edge and extending in a radial direction across a span, wherein the at least one cooling channel is a plurality of cooling channels, each cooling channel of the plurality of cooling channels having an inlet and an outlet, and wherein the outlet of each cooling channel is defined at the cover outer surface adjacent the trailing edge.

[0123] A composite component according to any preceding clause, further comprising: a component cavity for receiving a cooling fluid, wherein the trailing edge is defined by a trailing edge portion positioned rearward of the component cavity, and wherein the insert is disposed in the trailing edge portion such that a centerline of the insert extending along the axial direction is closer to one of the pressure side or the suction side than to the other of the pressure side or the suction side.

[0124] A composite component according to any preceding clause, further comprising: a component cavity for receiving a cooling fluid, wherein the insert is positioned rearwardly of the component cavity, and wherein a supply channel extends from the component cavity to the inlet of each cooling channel of the plurality of cooling channels.

[0125] The composite component of any preceding clause, further comprising: a component cavity for receiving a cooling fluid, wherein the insert is positioned rearward of the component cavity, wherein the insert defines an insert cavity extending along at least a portion of the span, and wherein at least one supply channel extends from the component cavity to the insert cavity.

[0126] A composite component as claimed in any preceding clause, further comprising a component cavity for receiving a cooling fluid, wherein a supply channel extends from the component cavity to the inlet of the at least one cooling channel.

[0127] A composite component according to any preceding clause, further comprising: a component cavity for receiving a cooling fluid, wherein the composite component is an airfoil, the airfoil having a pressure side opposite a suction side and a leading edge opposite a trailing edge, the pressure side and the suction side extending in an axial direction between the leading edge and the trailing edge and extending in a radial direction across a span, and wherein the insert is positioned adjacent to the leading edge.

[0128] A composite component according to any preceding clause, further comprising: a component cavity for receiving a cooling fluid, wherein the composite component is an airfoil, the airfoil having a pressure side opposite a suction side and a leading edge opposite a trailing edge, the pressure side and the suction side extending in an axial direction between the leading edge and the trailing edge and extending in a radial direction across a span, wherein the insert is positioned between the leading edge and the trailing edge along the axial direction, and wherein the insert is positioned adjacent to one of the pressure side and the suction side.

[0129] A composite component according to any preceding clause, further comprising: a component cavity for receiving a cooling fluid; a supply channel; and an injection channel, wherein the at least one cooling channel is configured as an insert manifold for receiving the cooling fluid, wherein the insert manifold has a depth, the depth being perpendicular to a length defined between the inlet of the at least one cooling channel and the outlet of the at least one cooling channel, wherein the supply channel extends from a supply channel inlet defined at the component cavity to a supply channel outlet at the insert manifold, and wherein the injection channel extends from a injection channel inlet defined at the insert manifold to an injection channel outlet at the cover outer surface.

[0130] A composite component according to any preceding clause, wherein the composite component extends in a radial direction between an inner end and an outer end, wherein the insert extends in the radial direction from the inner end to the outer end, wherein the insert extends in a direction perpendicular to the radial direction between a first end and a second end, wherein the insert defines a serpentine cavity for receiving a cooling fluid, the serpentine cavity having a cavity inlet adjacent to one of the first end or the second end, and wherein the serpentine cavity includes at least a first direction change adjacent to one of the inner end or the outer end and a second direction change adjacent to the other of the inner end or the outer end.

[0131] A composite component as claimed in any preceding clause, wherein the composite component is a nozzle airfoil assembly comprising at least one of an inner band or an outer band, and wherein the insert is disposed in the at least one of the inner band or the outer band.

[0132] A composite component as recited in any preceding clause, wherein the nozzle airfoil assembly defines a component cavity, and wherein the inlet of the at least one cooling channel is defined at the component cavity.

[0133] A composite component as described in any preceding clause wherein the composite component is a shroud positioned radially adjacent a plurality of blades.

[0134] A composite component as in any preceding clause, wherein the insert defines a plurality of cooling channels, each cooling channel of the plurality of cooling channels having an inlet and an outlet, and wherein the outlet of each cooling channel of the plurality of cooling channels is defined at the cover outer surface.

[0135] A composite component as claimed in any preceding clause, wherein the insert comprises a plurality of heat transfer elements extending into the at least one cooling channel.

[0136] A composite component according to any preceding clause, wherein the at least one cooling channel is configured as an insert manifold for receiving a cooling fluid, wherein the insert manifold has a depth perpendicular to a length defined between the inlet of the at least one cooling channel and the outlet of the at least one cooling channel, and wherein the insert includes a plurality of heat transfer elements extending into the insert manifold.

[0137] A composite component according to any preceding clause, wherein the insert comprises a plurality of layers formed by: depositing layers of additive material on a bed of an additive manufacturing machine; and selectively directing energy from an energy source to the layers of additive material to melt a portion of the additive material, wherein the insert is integrally formed as a single, unitary component.

[0138] A composite part as in any preceding clause wherein the CMC outer portion surrounds the additively printed inner portion.

[0139] A method for forming a composite component for a gas turbine engine comprises: substantially surrounding an additively printed inner portion within a preform or a plurality of layups laminated thereon; and infiltrating the preform or the plurality of layups with silicon via chemical vapor infiltration or melt infiltration to form a CMC outer portion having a cap outer surface.

[0140] A method as in any preceding clause, wherein the additively printed interior defines at least one cooling channel having an inlet and an outlet.

[0141] A method as in any preceding clause, wherein the outlet of the at least one cooling channel is in fluid communication through the cover outer surface.

[0142] A method for forming a composite component comprises: forming an insert defining at least one cooling channel having an inlet and an outlet, the insert having an insert outer surface; disposing the insert within a composite cover having a cover outer surface, the composite cover surrounding the insert so that the composite cover contacts the insert outer surface, wherein the outlet of the at least one cooling channel extends to the cover outer surface.

[0143] A method as in any preceding clause, wherein the CMC outer portion surrounds the additively printed inner portion.

[0144] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the present disclosure, including making and using any device or system and performing any combined method. The patentable scope of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. These other examples are intended to fall within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A composite component for a gas turbine engine, characterized in that The composite component comprises: an additively printed interior portion, the additively printed interior portion defining at least one flow path feature, wherein the additively printed interior portion comprises SiC; a ceramic matrix composite (CMC) outer portion, the CMC outer portion formed on the additively printed inner portion such that the CMC outer portion substantially surrounds the additively printed inner portion, wherein the CMC outer portion comprises a fiber reinforced ceramic matrix and defines at least one cooling cavity, the at least one cooling cavity being fluidly coupled to the at least one flow path feature of the additively printed inner portion, wherein the fiber reinforced ceramic matrix comprises SiC.

2. The composite component according to claim 1, characterized in that in, The at least one flow path feature of the additively printed interior portion has a non-linear geometry.

3. The composite component according to claim 1, characterized in that in, The CMC outer portion defines a linear channel that fluidly couples the at least one flow path feature and the at least one cooling cavity.

4. The composite component according to claim 1, characterized in that in, The CMC outer portion defines a hollow airfoil having a cooling cavity therein, and wherein the at least one flow path feature extends non-linearly from the cooling cavity to an exterior surface of the hollow airfoil.

5. The composite component according to claim 4, characterized in that in, The hollow airfoil has a pressure side opposite a suction side and a leading edge opposite a trailing edge, the pressure side and the suction side extending in an axial direction between the leading edge and the trailing edge in a non-linear curved geometry and extending in a radial direction across a span, wherein the cooling cavity is positioned adjacent to the leading edge, and wherein at least one first flow path feature comprises a plurality of cooling channels spaced apart along the span, each cooling channel extending from an inlet in the cooling cavity adjacent to the suction side to an outlet at the trailing edge in a non-linear curved geometry along the axial direction conforming to the non-linear curved geometry of the suction side.

6. The composite component according to claim 1, characterized in that in, The at least one first flow path feature is a cooling channel having a primary flow direction and an interior surface defined by a plurality of heat transfer elements extending into the cooling channel non-parallel to the primary flow direction.

7. The composite component according to claim 1, characterized in that in, The CMC outer portion defines an airfoil, and the additively printed inner portion is positioned in a trailing edge region of the airfoil.

8. The composite component according to claim 1, characterized in that in, The CMC outer portion defines an airfoil, and the additively printed inner portion is positioned in a leading edge region of the airfoil.

9. The composite component according to claim 1, characterized in that in, The CMC outer portion defines an airfoil, and the additively printed inner portion is positioned adjacent a suction side of the airfoil.

10. The composite component according to claim 1, characterized in that in, The CMC outer portion defines a nozzle airfoil assembly including an inner band and an outer band, and the additively printed inner portion is positioned in at least one of the inner band or the outer band.

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