System and method for compacting ceramic composite material

Abstract

Systems and methods for compacting a ceramic composite material are provided. The present disclosure relates to a method for compacting a ceramic composite material comprising the steps of: (1) positioning a roller in contact with a ply surface of a ply of a ceramic composite material, where the ply is positioned on a compacting surface; (2) applying a compaction pressure to the plies using a roller such that the contact pressure is substantially uniformly distributed over the plies; and (3) with the roller in contact with the ply surface and applying a compaction pressure, moving the roller across the ply to conform the ply to the compacted surface.

Description

Technical Field

[0001] The present disclosure generally relates to composite manufacturing, and more particularly, to manufacturing non-polymer composite structures, such as ceramic matrix composites, and more specifically still, to systems and methods for compacting ceramic matrix composite materials. Background Art

[0002] Currently, the compaction of ceramic matrix composite plies on a layup tool is a manual operation using manual pressure, sweeping, and vacuum bagging techniques. This results in inconsistent and unstable compaction quality. These manual operations require skilled technicians and are time-consuming, requiring inspection and rework, thus leading to an extended overall life cycle time for compacting ceramic body composite plies on the layup tool. Therefore, those skilled in the art continue to research and work on developing ceramic matrix composite manufacturing.

[0003] The abstract of FR 3 133 334 A1 states: "The invention relates to a deposition roll for a fibrous structure, which comprises an undeformable core centered on the axis of rotation of the roll, characterized in that the roll further comprises a deformable outer skin which, in the absence of pressure applied to the roll, is concentrically held around the core by a layer of deformable material interposed between the skin and the core, and the roll further comprises at least one sensor capable of measuring the distance or the change in distance between the skin and the core".

[0004] The abstract of US2014 / 190629 A1 states: "An induction heating compaction system is provided. The system includes an induction heating member and a compaction member. The induction heating member is configured to generate an electromagnetic field at a selected frequency. The selected frequency heats at least one of the fibers and the matrix in the prepreg. The compaction member has at least a portion made of a material transparent to the selected frequency of the electromagnetic field generated by the induction heating member. The compaction member includes a cooling assembly configured and arranged to extract heat from the prepreg while compacting the prepreg".

[0005] The abstract of US2014 / 018057 A1 states: "A method for producing a ceramic matrix composite component includes forming a fiber preform from a plurality of fibrous structures, the plurality of fibrous structures including core-shell particles, the core-shell particles including a core portion formed of a ceramic material core and a shell formed of an adhesive layer, the adhesive defining the outer surface of the core-shell particles and completely coating the core portion of the ceramic material, and sintering the core-shell particles in the obtained fiber preform to form a ceramic matrix in its pores".

[0006] The abstract of 2017 / 274636A1 states: "An apparatus for placing material on a surface includes a housing, a motor coupled to the housing, and a drive member coupled to the housing and powered by the motor. The apparatus also includes at least one guiding chute that defines a guiding channel with the drive member. The apparatus also includes a laminating roller coupled to the housing adjacent to the guiding channel. The laminating roller includes a roller surface, and the guiding channel is configured to discharge a quantity of material onto the roller surface. The laminating roller is configured to deposit the material onto the surface". SUMMARY OF THE INVENTION

[0007] Examples of a method for compacting a ceramic composite material and a system for compacting a ceramic composite material are disclosed. The following is a non-exhaustive list of examples according to the subject matter of the present disclosure, which may or may not be claimed.

[0008] In an example, the disclosed method includes the steps of: (1) positioning a roller in contact with a laminate surface of a ceramic composite laminate, wherein the laminate is positioned on a compacting surface; (2) applying a compacting pressure to the laminate using the roller such that the contact pressure is substantially evenly distributed over the laminate; and (3) moving the roller across the laminate while the roller is in contact with the laminate surface and applying the compacting pressure, thereby conforming the laminate to the compacting surface and maintaining a desired thickness of the laminate of the ceramic composite material.

[0009] In another example, the disclosed method includes the steps of: (1) positioning a laminate of a ceramic composite material on a compacting surface, wherein the laminate of the ceramic composite material includes a ceramic reinforcement and a ceramic matrix; (2) positioning the roller in contact with the laminate surface of the laminate; (3) applying a compacting pressure to the laminate using the roller, wherein the compacting pressure is substantially uniform along the contact interface between the roller and the laminate; and (4) moving the roller across the laminate while the roller is in contact with the laminate surface and applying the compacting pressure, thereby conforming the laminate to the compacting surface and maintaining a desired thickness of the laminate of the ceramic composite material. This aspect or example may be combined with another of the described aspects / examples or may be provided as a separate aspect independent of the other described aspects / examples.

[0010] In an example, the disclosed system includes a roller that includes a core and a covering that surrounds the core. The covering is selected such that the compacting pressure applied to a laminate of the ceramic composite material is uniform along the contact interface between the roller and the laminate.

[0011] Other examples of the system and method will become apparent from the following detailed description, the drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a flow chart of an example method for compacting a ceramic composite material;

[0013] Figure 2 is a schematic block diagram of an example system for compacting a ceramic composite material;

[0014] Figure 3 is a schematic diagram of an example of the system;

[0015] Figure 4 is a schematic diagram of an example of a roller of the system;

[0016] Figure 5 is a schematic diagram of an example of a part of the system;

[0017] Figure 6 is a schematic diagram of an example of a part of the system;

[0018] Figure 7 is an illustration of the compaction pressure along the contact interface between the ceramic composite laminate and the roller;

[0019] Figure 8 is a schematic diagram of an example of a part of the system;

[0020] Figure 9 is a schematic diagram of an example of a part of the system;

[0021] Figure 10 is a flow chart of an example of a method for aircraft manufacturing and servicing; and

[0022] Figure 11 is a schematic block diagram of an example of an aircraft. DETAILED DESCRIPTION

[0023] Generally, with reference to Figures 1 to 9 , by way of example, the present disclosure relates to a method 1000 and a system 100 for compacting a ceramic composite material. The method 1000 and the system 100 facilitate improvements in ceramic matrix composite (CMC) manufacturing by providing a substantially uniform pressure distribution to maintain the desired thickness of the ceramic composite material, thereby preventing matrix migration and / or fabric deformation. Although the examples of the method 1000 and the system 100 provide specific advantages and benefits related to manufacturing ceramic matrix composite structures, the method 1000 and the system 100 can also be used in manufacturing other non-polymer composite structures.

[0024] Ceramic matrix composites (CMCs) are a subgroup of composite materials and a subgroup of ceramics. CMCs include ceramic fibers embedded in a ceramic matrix. Both the fibers and the matrix can include any ceramic material, which includes carbon and carbon fibers. In one or more examples, the ceramic composite 200 is a ceramic matrix composite and includes a ceramic reinforcement 204 and a ceramic matrix 208.

[0025] In one or more examples, the ceramic reinforcement 204 is pre-impregnated with the ceramic matrix 208. In such examples, the lamina 202 of the ceramic composite 200 can also be referred to as a CMC prepreg.

[0026] In one or more examples, the ceramic reinforcement 204 includes at least one of carbon reinforced fibers, silicon carbide reinforced fibers, alumina reinforced fibers, aluminum-silica reinforced fibers, aluminum nitride reinforced fibers, silicon nitride reinforced fibers, mullite reinforced fibers, silica / quartz reinforced fibers, basalt reinforced fibers, and zirconia reinforced fibers. Other suitable reinforcement materials can also be considered for use as the ceramic reinforcement 204.

[0027] In one or more examples, the ceramic matrix 208 includes at least one of a carbon matrix, a silicon carbide matrix, an alumina matrix, an alumina-silica matrix, an aluminum nitride matrix, a silicon nitride matrix, a mullite matrix, a geopolymer matrix, and a zirconia matrix. Other suitable matrix materials can also be considered for use as the ceramic matrix 208.

[0028] In one or more examples, the ceramic matrix 208 includes ceramic particles 212 dispersed in a suspension medium 214 (e.g., a fluid or other carrier). In one or more examples, the ceramic matrix 208 is an aqueous suspension (e.g., the suspension medium 214 includes an aqueous medium). In one or more examples, the ceramic matrix 208 is a non-aqueous suspension (e.g., the suspension medium 214 includes a non-aqueous medium). The ceramic matrix 208 has various viscosities depending on the suspension medium 214 used. In one or more examples, the ceramic particles 212 include at least one of carbon particles, silicon carbide particles, alumina particles, alumina-silica particles, aluminum nitride particles, silicon nitride particles, mullite particles, geopolymer particles, and zirconia particles. Other suitable materials can also be considered for use as the ceramic particles 212.

[0029] Typically, the reinforcement materials (e.g., the ceramic reinforcement 204) of fabric-based ceramic matrix composites are more brittle than those of fabric-based polymer matrix composites (PMCs). Additionally, the viscosity of the matrix material (e.g., the ceramic matrix 208) of fabric-based ceramic matrix composites is lower than that of fabric-based polymer matrix composites. Therefore, traditional compaction techniques and tools used for polymer matrix composites are not suitable for ceramic matrix composites.

[0030] Pick-and-place (PnP) robotic layup of fabric-based ceramic matrix composites (e.g., CMC prepregs) requires ply and splice compaction during layup to remove voids and wrinkles and to conform the prepreg to the tool before applying each subsequent ply. Examples of method 1000 and system 100 utilize special rollers to compact the plies in a manner similar to the smoothing process used during manual layup. In one or more examples, the rollers are integrated into the robotic end effector. In one or more examples, system 100 and method 1000 provide the ability to adjust the compaction pressure during compaction molding.

[0031] The material for the roller is selected such that the roller can be used to compact the CMC prepreg while maintaining the desired thickness of the prepreg without causing migration of the ceramic matrix or deformation of the reinforcement of the CMC prepreg. In one or more examples, a pressure sensor film is used to evaluate several materials to determine a uniform pressure distribution to maintain the desired thickness and without causing migration of the ceramic matrix or deformation of the ceramic reinforcement of the CMC prepreg, e.g., using a feedback control system. In one or more examples, the results of the material validation process help to downselect several materials to a closed-cell silicone foam with a Shore A5 medium soft hardness. The hardness of the material can be measured with a Shore durometer (or any other suitable device). The higher the number on the scale, the greater the resistance to indentation and thus the harder the material. Lower numbers indicate less resistance and softer materials. Advantageously, the compliance of the selected roller material provides pressure uniformity without local high pressure peaks. The softness of the selected roller material allows the CMC prepreg to be smoothed while maintaining the desired thickness and without reinforcement deformation or matrix migration, while effectively eliminating large trapped air bubbles. The selected material is also easy to clean.

[0032] It is recognized that the automated foam roller compaction provided by method 1000 and system 100 disclosed herein is advantageous in fabric-based CMC layup processing, which can provide key attributes for optimal ply consolidation to obtain the desired material properties. These key attributes include: applying uniform pressure to the ply sheets and splices; flattening the ply sheets and splices and conforming them to the tool surface; removing large trapped air bubbles between ply stacks to minimize voids and porosity; spreading the matrix distribution evenly; minimizing or eliminating ply bridging in corners and concave regions.

[0033] Figure 1 is a flowchart illustrating an example of method 1000. Figure 2 is a schematic block diagram of an example of system 100. Method 1000 and system 100 are applicable to automated pick-and-place and ply consolidation of fabric-based ceramic matrix prepregs, which results in improved part quality and reduced rework.

[0034] Figure 3 An example of system 100 is schematically illustrated. The illustrated example depicts a roller 102 integrated with a robotic end effector 150 that is capable of adjusting the compaction pressure 114 applied by the roller 102 during the compaction molding of the plies 202 of the ceramic composite material 200 using the roller 102. The material of the roller 102 is selectively customized, and the applied compaction pressure 114 is selectively controlled to be high enough to expel the trapped air between the plies, but not too high to cause matrix migration or pre-preg fabric deformation.

[0035] Figure 4 An example of the roller 102 is schematically illustrated. Method 1000 and system 100 utilize a specific compaction roller with a softness that is selected for compacting and forming a suspension-based CMC pre-preg without causing matrix migration and pre-preg fabric deformation.

[0036] Figure 5 An example of system 100 is schematically illustrated. In one or more examples, system 100 is used to test and validate different types of materials used on the roller 102. In these examples, system 100 utilizes a pressure sensor diaphragm 144 to measure the compaction pressure 114 applied by the test roller 136 to the test compaction surface 164. Thus, various examples of test rollers 136 with different material properties can be tested to select the desired or suitable material (e.g., Figure 3 and Figure 4 ) for use on the roller 102, and the test roller applies the compaction pressure 114 evenly on the plies 202.

[0037] Figure 6 An example of system 100 is schematically illustrated. The illustrated example depicts using the roller 102 to compact the plies 202 of the ceramic composite material 200 by applying the compaction pressure 114 as the roller 102 moves along the compaction path 160. Figure 7 An example of the compaction pressure 114 being applied at least approximately evenly by the roller 102 is graphically illustrated.

[0038] Figure 8 An example of system 100 is schematically illustrated. In one or more examples, system 100 includes a pressure sensor diaphragm 144 to measure the compaction pressure 114 applied by the roller 102 to the plies 202 during compaction. In these examples, system 100 is configured to: in response to the measurement value generated by the pressure sensor diaphragm 144 and using a feedback controller 152 ( Figure 2 ) to adjust the compaction pressure 114 such that the compaction pressure 114 is applied evenly to the plies 202 by the roller 102.

[0039] Figure 9 FIG. 2 schematically illustrates an example of system 100. The illustrated example depicts a roller 102 that is used to compact a laminate overlap splice (referred to as splice joint 216). In the illustrated example, the multiple laminates have an uneven laminate surface, and at least one of the laminates has an exposed laminate edge 218. In these examples, the material of the roller 102 is selected such that the compaction pressure 114 is uniformly applied by the roller 102 to the splice joint 216 of the laminates.

[0040] With specific reference Figure 1 and general reference Figures 2 to 9 , the following are examples of method 1000 according to the present disclosure. In one or more examples, method 1000 is implemented using system 100 or roller 102 (e.g., Figures 2 to 9 ). Method 1000 includes multiple elements, steps, and / or operations. In one example, not all of the described or illustrated elements, steps, and / or operations are necessary for that example. Some or all of the elements, steps, and / or operations described or illustrated in one example can be combined in various ways with other examples without including the other elements, steps, and / or operations described in those other examples, even if such combinations are not explicitly described or illustrated by example herein.

[0041] In one or more examples, one or more steps of method 1000 are electronically controlled or computer controlled (e.g., under the guidance of computer 168). Thus, in one or more examples, method 1000 is an electronic controller method or a computer-implemented method.

[0042] Referring Figure 1 , in one or more examples, method 1000 includes the step of positioning the laminate 202 of the ceramic composite material 200 on the compaction surface 104 (block 1002). The compaction surface 104 can have any suitable size, shape, or geometry. The compaction surface 104 provides the shape of the laminate 202 of the ceramic composite material 200 and any subsequent placed laminates after compaction. In one or more examples, the compaction surface 104 is planar (e.g., generally flat). In one or more examples, at least a portion of the compaction surface 104 includes a contour. In one or more examples, the laminate 202 of the ceramic composite material 200 is initially set in a planar (e.g., substantially flat) form, such as in the form of a sheet or strip 200 of the ceramic composite material. The laminate 202 can be placed on the compaction surface 104 using any suitable method, such as manually or automatically using a suitable pick-and-place end effector.

[0043] Referring Figure 1, in one or more examples, method 1000 includes the step of providing a roller 102 (block 1004). Roller 102 is a compaction roller used to compact the lamina 202 of ceramic composite 200 onto a compaction surface 104. In addition to compaction, the purpose of roller 102 is to provide a controlled deformation of the fabric structure of lamina 202 (e.g., ceramic reinforcement 204) to conform to the surface profile of compaction surface 104, such as a complex profile. Roller 102 is configured to interact with the fiber stiffness of ceramic reinforcement 204 to shear the material weave of the fabric of ceramic reinforcement 104 during placement, thereby allowing some movement of the fibers to conform the initially flat lamina to the profile of compaction surface 104. When the lamina 202 of ceramic composite 200 conforms to the shape of compaction surface 104, this enables the weave of the ceramic fabric to deform to some desired, suitable, or necessary extent. As will be described in more detail herein, the material for roller 102 is selected, more specifically the softness / hardness of the roller material, the compaction force applied by roller 102 to lamina 202, the uniformity of the compaction force applied by roller 102 to lamina 202, and other parameters are selected to maintain the desired thickness of lamina 202 and not cause migration of the ceramic matrix 208 of lamina 202 of ceramic composite 200 and not cause deformation of the ceramic reinforcement 204 of lamina 202 of ceramic composite 200. In other words, in various examples, roller 102 is capable of making the compaction force applied by roller 102 to lamina 202 uniform, thereby enabling the fabric structure of the ceramic reinforcement 204 of lamina 202 to conform to compaction surface 104 while maintaining the desired thickness of lamina 202, but preventing migration of the ceramic matrix 208 and / or deformation of the fabric structure of the ceramic reinforcement 204 of lamina 202, which would result in an undesired thickness of lamina 202.

[0044] For the purposes of the present disclosure, the term "conformance" and like terms used in connection with the compaction of the lamina 202 of the ceramic composite 200 (e.g., applying a compaction pressure 114 to the lamina 202) refer to the desired or appropriate degree of deformation of the fabric structure (e.g., the ceramic reinforcement 204) of the lamina 202, such as in the form of shear of a woven pattern, necessary to conform the lamina 202 to the desired profile of the compaction surface 104. As an example, the roller 102 is configured to form the material of the lamina 202 onto the compaction surface 104 without deforming the fabric material of the ceramic reinforcement 204, whether the compaction surface is flat or has a wavy profile. In one or more examples, initially the lamina 202 has a substantially flat configuration. When the lamina 202 is placed on the compaction surface 104, the compaction pressure 114 is applied to the lamina 202 by the roller 102 such that the lamina 202 conforms to the profile (e.g., flat, curved, or any other simple or complex profile). When conforming to the profile of the compaction surface 104, the material of the lamina 202 (e.g., the ceramic reinforcement 204) must deform to some extent, such as in the form of shear of a woven pattern, e.g., from at least an approximately orthogonal woven pattern to a non-orthogonal woven pattern.

[0045] For the purposes of the present disclosure, the term "distortion" and like terms used in connection with the compaction of the lamina 202 of the ceramic composite 200 (e.g., applying a compaction pressure 114 to the lamina 202) refer to an undesired or inappropriate degree of deformation of the fabric structure (e.g., the ceramic reinforcement 204) of the lamina 202 that exceeds the degree necessary to acceptably conform to the profile of the compaction surface 104 or is insufficient to acceptably conform to the profile of the compaction surface 104. Examples of such distortion of the lamina 202 in response to compaction include, but are not limited to, wrinkling, blistering, pleating, pouting, bridging, or other deformations in the ceramic reinforcement 204.

[0046] For the purposes of the present disclosure, the "desired thickness" of the lamina 202 of the ceramic composite 200 refers to the desired thickness (e.g., through-thickness) of the ceramic reinforcement 204 impregnated with or embedded in the ceramic matrix 208 during or after compaction by the roller 102. Migration of the ceramic matrix 208 refers to the undesired spreading of the ceramic matrix 208 in response to the compaction pressure 114 applied to the lamina 202 by the roller 102. Thus, migration of the ceramic matrix 208 and / or deformation of the ceramic reinforcement 204 results in an undesired thickness.

[0047] Referring to Figure 1 and Figure 2, in one or more examples, method 1000 includes the step of compressing laminate 202 of ceramic composite material 200 on a compaction surface 104 (block 1006). This compaction step (block 1006) is performed using system 100, and more specifically, using roller 102. In one or more examples, the compaction step (block 1006) is electronically controlled or computer controlled (e.g., under the guidance of computer 168). Generally, the compaction step (block 1006) conforms the ceramic reinforcement 204 of laminate 202 to the profile 158 of the compaction surface 104 and maintains the desired thickness of laminate 202, thereby preventing migration of the ceramic matrix 208 of laminate 202 and / or deformation of the ceramic reinforcement 204 of laminate 202.

[0048] Referring to Figure 1 and Figure 2 , in one or more examples, method 1000, such as the compaction step (block 1006), includes the step of positioning roller 102 in contact with laminate surface 210 of laminate 202 of ceramic composite material 200 (block 1008). Roller 102 is positioned against laminate 202, and laminate 202 is positioned on compaction surface 104. Roller 102 can be positioned automatically by any suitable method (e.g., using a robotic arm, an overhead gantry, one or more actuators, etc. or a combination thereof), which are configured to controllably position and move roller 102 in three-dimensional space, e.g., under the guidance of a controller.

[0049] Referring to Figure 1 and Figure 2 , in one or more examples, method 1000, such as the compaction step (block 1006), includes the step of applying compaction pressure 114 to laminate 202 (block 1012). Compaction pressure 114 is applied using roller 102 such that compaction pressure 114 is distributed substantially uniformly over laminate 202. Compaction pressure 114 refers to the compaction force applied by roller 102 to laminate 202 at the contact interface 116 between roller surface 120 of roller 120 and laminate surface 210 of laminate 202. Compaction pressure 114 can be applied by roller 102 by any suitable method, e.g., automatically using a robotic arm, an overhead gantry, one or more actuators, etc. or a combination thereof, which are configured to controllably position and move roller 102 in three-dimensional space, e.g., under the guidance of a controller.

[0050] Referring to Figure 1 and Figure 2, in one or more examples, method 1000, such as the compaction step (block 1006), includes: moving roller 102 across laminate 202 while maintaining the desired thickness of laminate 202 and thus without causing migration of ceramic matrix 208 or deformation of ceramic reinforcement 204 of laminate 202 of ceramic composite 200, in the case where roller 102 contacts laminate surface 210 (block 1008) and applies compaction pressure 114 (block 1012). Roller 102 moves along compaction path 160. Roller 102 can be moved across laminate surface 210 of laminate 202 by any suitable method (e.g., automatically using a robotic arm, an overhead gantry, one or more actuators, etc. or a combination thereof), which are configured to controllably position and move roller 102 in three-dimensional space, e.g., under the guidance of a controller).

[0051] Referring to Figure 1 and Figure 2, in one or more examples, method 1000 includes a step of selecting a compaction pressure 114 (block 1010). As an example, this selection step (block 1010) includes a step of selecting a magnitude 122 of the compaction pressure 114. Generally, the magnitude 122 of the compaction pressure 114 refers to a measurable amount of the compaction force on the contact interface 116 (e.g., area) between the roller surface 120 and the laminate surface 210. The magnitude 122 of the compaction pressure 114 is selected to remove voids from the laminate 202, remove wrinkles from the laminate 202, and conform the laminate 202 to the compaction surface 104 while moving the roller 102 across the laminate 202. The magnitude 122 of the compaction pressure 114 is selected to allow the laminate 202 to conform, e.g., shear of the fabric texture of the ceramic reinforcement 204 of the laminate 202, without causing deformation of the fabric texture of the ceramic reinforcement 204 of the laminate 202, such as wrinkling, blistering, pleating, pouting, and / or bridging, and without causing migration of the ceramic matrix 208 of the laminate 202 while moving the roller 102 across the laminate 202. Thus, the compaction pressure 114 applied by the roller 102 is selected for compressing the laminate 202 of the ceramic composite 200 onto the compaction surface 104. In addition to compaction, the selected magnitude 122 of the compaction pressure 114 provides a controlled conformity (e.g., shear) of the fabric texture (e.g., ceramic reinforcement 204) of the laminate 202 without deformation (e.g., wrinkling) to conform to the surface profile shape of the compaction surface 104, such as a complex profile. The compaction pressure 114 and the selected roller material for the roller 102 are configured to interact with the fiber stiffness of the ceramic reinforcement 204 to shear the material texture of the fabric of the ceramic reinforcement 204 during placement, thereby allowing some movement of the fibers to conform the initially flat laminate to the profile of the compaction surface 104. This allows the texture of the ceramic fabric to deform to the desired or necessary extent as the laminate 202 of the ceramic composite 200 conforms to the shape of the compaction surface 104, but not to an extent that exceeds what is acceptable to conform to the profile of the compaction surface 104.

[0052] Referring to Figure 2 and Figure 3 , in one or more examples, according to method 1000, the compaction surface 104 includes or takes the form of the tool surface 108 of the tool 106. The tool 106 includes any suitable lamination tool, forming tool, mandrel tool, etc., which is configured to support and provide the underlying shape of the lamination of multiple laminates (e.g., stacks) of the ceramic composite 200. In one or more examples, the tool surface 108 is planar (e.g., generally flat). In one or more examples, at least a portion of the tool surface 108 includes a profile.

[0053] Referring to Figure 2 andFigure 3 , in one or more examples, according to method 1000, the compaction surface 104 includes or takes the form of the prior lamina surface 112 of a prior lamina 110 of the ceramic composite 200. The prior lamina 110 refers to a lamina of the ceramic composite 200 that has been previously placed and compacted on the tool 106. In one or more examples, the prior lamina surface 112 is planar (e.g., substantially flat). In one or more examples, at least a portion of the prior lamina surface 112 includes a profile.

[0054] Referring Figure 2 , Figure 6 and Figure 7 , in one or more examples, according to method 1000, the compaction pressure 114 is uniform along the contact interface 116 between the roller surface 120 of the roller 102 and the lamina surface 210 of the lamina 202. The roller 102 is configured to apply the compaction pressure 114 uniformly across the contact interface 116 for any desired surface profile, such as a flat surface, a curved surface, or any other profiled surface. Thus, the roller 102 is configured to conform to the surface profile shape of the compaction surface 104 on any surface profile without a significant change in the pressure distribution. In one or more examples, the contact interface 116 is defined by or corresponds to the width W of the roller 102. Generally, and as Figure 7 illustrated in, the uniformity of the compaction pressure 114 along the contact interface 116 refers to the degree of variation 118 of the compaction pressure 114 along the contact interface 116 during compaction of the lamina 202 (block 1006). The variation 118 refers to the change or difference of the compaction pressure 114 within the area formed by the contact interface 116 between the roller surface 120 of the roller 102 and the lamina surface 210 of the lamina 202 while moving the roller 102 along or in the direction of the compaction path 160. In one or more examples, the compression of the material of the roller 102 (e.g., a relatively soft material) provides the compaction force, which will naturally introduce some variation depending on the amount of compression of the roller 102 at any point along the contact interface 116 and the stiffness of the material of the roller 102. As will be described in more detail herein, the material of the roller 102 is selected such that the compaction pressure 114 applied by the roller 102 to the lamina 202 is at least approximately uniform along the contact interface 116.

[0055] Referring Figure 2 and Figure 7, in one or more examples, according to method 1000, the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI). In one or more examples, according to method 1000, the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 20.6843 kPa (3 PSI). In one or more examples, according to method 1000, the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 6.8948 kPa (1 PSI).

[0056] Refer to Figure 2 and Figures 4 to 6 , in one or more examples, according to method 1000, the roller 102 includes a core 124 and a covering 126. The covering 126 surrounds the core 124. In one or more examples, the core 124 is solid. In one or more examples, the core 124 is hollow. The core 124 can be made of any of a variety of suitable materials or combinations thereof. The covering 126 can be made of any of a variety of suitable materials or combinations thereof.

[0057] Refer to Figure 2 , in one or more examples, according to method 1000, the covering 126 includes a foam 128. The foam 128 selected as the material for the covering 126 of the roller 102 provides a relatively soft material that causes the compaction pressure 114 applied by the roller 102 to the laminate 202 to be at least approximately uniform along the contact interface 116 within the expected surface profile.

[0058] Refer to Figure 2 , in one or more examples, according to method 1000, the foam 128 includes a closed-cell foam 130. The closed-cell foam 130 selected as the material for the covering 126 of the roller 102 provides a relatively soft material that causes the compaction pressure 114 applied by the roller 102 to the laminate 202 to be at least approximately uniform along the contact interface 116. The closed-cell foam 130 as the material for the covering 126 of the roller 102 also provides the roller surface 120 of the roller 102, which is resistant or impermeable to the ceramic matrix 208 of the ceramic composite 200.

[0059] Refer to Figure 2, in one or more examples, according to method 1000, the covering 126 includes an inflatable bladder 132. The inflatable bladder 132, which is the material selected for the covering 126 of the roller 102, provides a relatively soft material that enables the compaction pressure 114 applied by the roller 102 to the laminate 202 to be at least approximately uniform along the contact interface 116. The inflatable bladder 132, which is the material selected for the covering 126 of the roller 102, also provides the roller surface 120 of the roller 102 that is resistant or impermeable to the ceramic matrix 208 of the ceramic composite 200. The inflatable bladder 132, which is the material selected for the covering 126 of the roller 102, can also selectively control the softness and hardness of the roller 102 by changing the internal pressure of the inflatable bladder 132 without the need to replace the roller 102.

[0060] Refer to Figure 2 , in one or more examples, according to method 1000, the covering 126 is impermeable. The impermeable material selected for the covering 126 of the roller 102 provides the roller surface 120 of the roller 102 that is impermeable to the ceramic matrix 208 of the ceramic composite 200.

[0061] Refer to Figure 2 , in one or more examples, according to method 1000, the covering 126 includes a Shore A hardness between approximately 1 and 10. In one or more examples, according to method 1000, the covering 126 includes a Shore A hardness between about 3 and 7. In one or more examples, according to method 1000, the covering 126 includes a Shore A hardness of about 5. Through testing and verification, it has been determined that selecting and using a material for the covering 126 with a Shore A hardness between approximately 1 and 10 (e.g., between about 3 and 7, e.g., about 5) can enable the compaction pressure 114 applied by the roller 102 to the laminate 202 to be at least approximately uniform along the contact interface 116. For example, the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI), e.g., less than 20.6843 kPa (3 PSI), e.g., less than 6.8948 kPa (1 PSI).

[0062] Refer to Figure 2, in one or more examples, according to method 1000, the covering 126 includes silicone, such as closed-cell silicone foam or inflatable silicone airbag. In one or more examples, according to method 1000, the covering 126 includes urethane, such as closed-cell urethane foam or inflatable urethane airbag. In one or more examples, according to method 1000, the covering 126 includes polyurethane, such as closed-cell polyurethane foam or inflatable polyurethane airbag. In one or more examples, according to method 1000, the covering 126 includes latex, such as closed-cell latex foam or inflatable latex airbag.

[0063] Refer to Figure 1 and Figure 2 , in one or more examples, method 1000 includes a step of selecting a covering material 134 for the covering 126 (block 1016). The covering material 134 is selected such that when the roller 102 is moved across the laminate 202, the compaction pressure 114 is uniform along the contact interface 116 between the roller 102 and the laminate 202 (block 1014).

[0064] Refer to Figure 1 and Figure 2 , in one or more examples, according to method 1000, the covering material 134 is selected such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI). In one or more examples, according to method 1000, the covering material 134 is selected such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 20.6843 kPa (3 PSI). In one or more examples, according to method 1000, the covering material 134 is selected such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 6.8948 kPa (1 PSI).

[0065] Refer to Figure 1 and Figure 2 , in one or more examples, method 1000, such as the selection step (block 1016), includes a step of providing a test roller 136 (block 1018). The test roller 136 includes a test core 138 and a test covering 140 surrounding the test core 138. The test covering 140 includes a test covering material 142. In these examples, the test covering material 142 is selected from various material options having different material compositions (e.g., silicone, urethane, polyurethane, latex, etc.), different material structures (e.g., foam, closed-cell foam, inflatable airbag, etc.), and different hardnesses (e.g., Shore A hardness between about 1 and 10, Shore A hardness between about 3 and 7, Shore A hardness about 5, etc.).

[0066] Refer to Figure 1 , Figure 2 ,Figure 5 and Figure 7 , in one or more examples, method 1000, such as the selection step (block 1016), includes the step of positioning test roller 136 in contact with pressure sensor film 144 (block 1020). Pressure sensor film 144 includes any suitable tactile pressure sensor or is in the form of any suitable tactile pressure sensor that is configured or otherwise operates to measure the force and pressure distribution between contacting surfaces (including flat or contoured surfaces). In one or more examples, pressure sensor film 144 measures and maps the interface pressure between test roller 136 and underlying test compression surface 164 while moving test roller 136 across pressure sensor film 44 using a thin and flexible sensor and feedback controller 152 positioned between test roller surface 162 and test roller 136 and underlying test compression surface 164 (e.g., Figure 7 ). The final pressure data 166 generated by pressure sensor film 144 (e.g., as illustrated in Figure 7 ) can be analyzed using computational analysis tools or other software applications and programs that provide an understanding of enhanced material selection, movement speed, compaction pressure, pressure uniformity, etc. Thus, for example, measurement of compaction pressure helps to better understand one or more of the above aspects. This can improve the compaction process.

[0067] Referring to Figure 1 、 Figure 2 and Figure 5 , in one or more examples, method 1000, such as the selection step (block 1016), includes the step of applying compaction pressure 114 to pressure sensor film 144 using test roller 136 (block 1022).

[0068] Referring to Figure 1 、 Figure 2 and Figure 5 , in one or more examples, with test roller 136 in contact with pressure sensor film 144 (block 1020) and applying compaction pressure 114 (block 1022), method 1000, such as the selection step (block 1016), includes the step of moving test roller 136 across pressure sensor film 144 (block 1024).

[0069] Referring to Figure 1 、 Figure 2 and Figure 5, in one or more examples, method 1000, such as the selection step (block 1016), includes the step of measuring the compaction pressure 114 (block 1026) while moving the test roll 136 across the pressure sensor film 144 in the direction of the compaction path 160. The compaction pressure 114 is measured using the pressure sensor film 144, which provides pressure data 166 that is analyzed, for example, by the computer 168.

[0070] Refer to Figure 1 and Figure 2 , in one or more examples, method 1000, such as the selection step (block 1016), includes the following step (block 1028) of determining whether the compaction pressure 114 is uniform along the test contact interface 146 between the test roll 136 and the pressure sensor film 144 when moving the test roll 136 across the pressure sensor film 144.

[0071] Refer to Figure 1 and Figure 2 , in one or more examples, method 1000, such as the selection step (block 1016), includes the step of verifying the test cover material 142 (block 1030) when the compaction pressure 114 is uniform along the test contact interface 146. In the case where the test cover material 142 being tested provides a non-uniform compaction pressure 114 (e.g., the variation 118 is greater than the desired threshold) along the test contact interface 146, this situation of the test cover material 142 is considered unsatisfactory for the cover material 134 used for the roll 102. In the case where the test cover material 142 being tested provides a uniform compaction pressure 114 (e.g., the variation 118 is less than or equal to the desired threshold) along the test contact interface 146, this situation of the test cover material 142 is considered satisfactory for the cover material 134 used for the roll 102.

[0072] Refer to Figure 1 , in one or more examples, according to method 1000, any number of different types or variants (e.g., repetitions) on the test cover material 142 can be subjected to the selection step (block 1016) any number of times until one or more are verified as suitable for use as the cover material 134 for the roll 102.

[0073] Refer to Figure 1 and Figure 2, in one or more examples, according to method 1000, such as the verification step (block 1030), when the variation 118 of the compaction pressure 114 along the test contact interface 146 is less than 34.4748 kPa (5 PSI), the compaction pressure 114 is determined to be uniform. In one or more examples, according to method 1000, such as the verification step (block 1030), when the variation 118 of the compaction pressure 114 along the test contact interface 146 is less than 20.6843 kPa (3 PSI), the compaction pressure 114 is determined to be uniform. In one or more examples, according to method 1000, such as the verification step (block 1030), when the variation 118 of the compaction pressure 114 along the test contact interface 146 is less than 6.8948 kPa (1 PSI), the compaction pressure 114 is determined to be uniform.

[0074] Referring to Figure 1 , Figure 2 and Figure 8 , in one or more examples, method 1000 includes the step (block 1032) of measuring the compaction pressure 114 while compacting the laminate 202 (block 1006) (e.g., while moving the roller 102 across the laminate 202 (block 1014)). The pressure sensor film 144 is used to measure the compaction pressure 114 (block 1032), and the pressure sensor film provides pressure data 166 that is analyzed, for example, by the computer 168.

[0075] Referring to Figure 1 , Figure 2 and Figure 8 , in one or more examples, method 1000 includes the step of adjusting the compaction pressure 114 (block 1046) in response to the measurement (block 1032) when the compaction pressure 114 is non-uniform along the contact interface 116 between the roller 102 and the laminate 202. In one or more examples, while moving the roller 102 across the pressure sensor film 44, the pressure sensor film 144 measures and maps the interface pressure between the roller 102 and the laminate 202 using a thin and flexible sensor positioned between the roller surface 120 of the roller 102 and the underlying instance of the laminate 202 and a feedback controller 152 (e.g., Figure 7 ). The final pressure data 166 generated by the pressure sensor film 144 (e.g., as illustrated in Figure 7 ) can be analyzed using computational analysis tools or other software applications and programs to adjust the compaction pressure 114.

[0076] Referring to Figure 1 , Figure 2 and Figure 8, in one or more examples, method 1000, such as the measuring step (block 1032), includes positioning the pressure sensor diaphragm 144 in contact with the laminate surface 210 of the laminate 202 (block 1034).

[0077] Referring Figure 1 、 Figure 2 and Figure 8 , in one or more examples, method 1000, such as the measuring step (block 1032), includes positioning the roller 102 in contact with the pressure sensor diaphragm 144 (block 1036). In one or more examples, when measuring the compaction pressure 114 (block 1032), this positioning step (block 1036) replaces or represents the positioning step during compaction (block 1008).

[0078] Referring Figure 1 、 Figure 2 and Figure 8 , in one or more examples, method 1000, such as the measuring step (block 1032), includes applying the compaction pressure 114 to the pressure sensor diaphragm 144 using the roller 102 (e.g., applying to the laminate 202 through the pressure sensor diaphragm 44) (block 1038). In one or more examples, when measuring the compaction pressure 114 (block 1032), this applying step (block 1038) replaces or represents the applying step during compaction (block 1012).

[0079] Referring Figure 1 、 Figure 2 and Figure 8 , in one or more examples, with the roller 102 in contact with the pressure sensor diaphragm 144 (block 1036) and applying the compaction pressure 114 (block 1038), method 1000, such as the measuring step (block 1032), includes moving the roller 102 across the pressure sensor diaphragm 144 (block 1040). In one or more examples, when measuring the compaction pressure 114 (block 1032), this moving step (block 1040) replaces or represents the moving step during compaction (block 1014).

[0080] Referring Figure 1 、 Figure 2 and Figure 8 , in one or more examples, method 1000, such as the measuring step (block 1032), includes measuring the compaction pressure 114 while moving the roller 102 across the pressure sensor diaphragm 144 (block 1040) (block 1042).

[0081] Referring Figure 1 、 Figure 2 and Figure 8, in one or more examples, method 1000, such as the measuring step (block 1032), includes the following steps (block 1044), namely: determining whether the compaction pressure 114 is uniform along the contact interface 116 between the roller 102 and the pressure sensor membrane 144 when the roller 102 is moved across the pressure sensor membrane 144 (block 1040). In a case where the compaction pressure 114 is determined to be uniform along the contact interface 116 (e.g., the variation 118 is less than or equal to a desired threshold), the compaction is continued by moving the roller 102 further along the compaction path 160 (block 1006). In a case where it is determined that the compaction pressure 114 is not uniform along the contact interface 116 (e.g., the variation 118 is greater than the desired threshold), the compaction pressure 114 is adjusted (block 1046).

[0082] Referring to Figure 1 , thus, in one or more examples, the method 1000 for compacting the ceramic composite 200 includes the step of positioning the laminate 202 of the ceramic composite 200 on the compaction surface 104. The laminate 202 of the ceramic composite 200 includes the ceramic reinforcement 204 and the ceramic matrix 208. The method 1000 includes the step of positioning the roller 102 in contact with the laminate surface 210 of the laminate 202. The method 1000 includes the step of applying the compaction pressure 114 to the laminate 202 using the roller 102. The compaction pressure 114 is generally uniformly distributed along the contact interface 116 between the roller 102 and the laminate 202. In a case where the roller 102 is in contact with the laminate surface 210 and applies the compaction pressure 114, the method 1000 includes the step of moving the roller 102 across the laminate 202 while maintaining the required thickness of the laminate 202 and thus without causing migration of the ceramic matrix 208 or deformation of the ceramic reinforcement 204 of the laminate 202 of the ceramic composite 200.

[0083] Referring to Figure 1 and Figure 2 , in one or more examples, the method 1000 includes the step of providing a roller 102. The roller 102 includes a core 124. The roller 102 includes a covering 126 surrounding the core 124. The covering 126 includes a closed-cell foam 130. The closed-cell foam 130 includes a Shore A hardness of approximately 5.

[0084] Now referring to Figures 2 to 8, the following is an example of system 100 according to the present disclosure. System 100 includes a plurality of elements, features, and components. Not all elements, features, and / or components described or illustrated in one example are required in that example. Some or all of the elements, features, and / or components described or illustrated in one example can be combined with other examples in various ways without including other elements, features, and / or components described in those other examples, even if such combinations or these combinations are not explicitly described or illustrated by examples herein.

[0085] Now refer to Figures 2 to 4 , Figure 6 and Figure 7 , in one or more examples, system 100 includes a roller 102. Roller 102 includes a core 124 and a covering 126 surrounding the core 124. The covering 126 is selected such that the compaction pressure 114 applied to the laminate 202 of the ceramic composite 200 is uniform along the contact interface 116 between the roller 102 and the laminate 202.

[0086] Now refer to Figure 2 and Figure 3 , in one or more examples, system 100 includes a robotic manipulator 148. In one or more examples, robotic manipulator 148 includes a robotic arm 154 and an end effector 150 coupled to the end of the robotic arm 154. Roller 102 is coupled to end effector 150. In one or more examples, robotic manipulator 148 positions roller 102 in contact with the laminate surface 210 of laminate 202 of ceramic composite 200, which laminate surface is positioned on compaction surface 104. In one or more examples, robotic arm 154 positions roller 102 relatively close to the laminate surface 210 of laminate 202, and end effector 150 positions roller 102 in contact with the laminate surface 210 of laminate 202. As an example, a robotic manipulator 148, such as end effector 150, includes at least one actuator 156 configured to: move roller 102 relative to robotic arm 154 and / or end effector 150, and position roller 102 in contact with the laminate surface 210 of laminate 202.

[0087] Now refer to Figure 2 and Figure 3, in one or more examples, the robotic manipulator 148 uses the roller 102 to apply a compaction pressure 114 to the sheet 202. In one or more examples, the robotic arm 154 moves the roller 102 relative to the compaction surface 104 to apply the compaction pressure 114 to the sheet 202. In one or more examples, the end effector 150 moves the roller 102 relative to the compaction surface 104 to apply the compaction pressure 114 to the sheet 202. As an example, a robotic manipulator 148 such as the end effector 150 includes at least one actuator 156 configured to: move the roller 102 relative to the robotic arm 154 and / or the end effector 150, and apply the compaction pressure 114 to the sheet 202 using the roller 102.

[0088] Now refer to Figure 2 and Figure 3 , in one or more examples, with the roller 102 in contact with the sheet surface 210 and applying the compaction pressure 114, the robotic manipulator 148 moves the roller 102 across the sheet 202. In one or more examples, while applying the compaction pressure 114 to the sheet 202, the robotic arm 154 moves the roller 102 across the sheet 202 in a compaction path 160. In one or more examples, while applying the compaction pressure 114 to the sheet 202, the end effector 150 moves the roller 102 across the sheet 202 in a compaction path 160. As an example, a robotic manipulator 148 such as the end effector 150 includes at least one actuator 156 configured to: move the roller 102 and apply the compaction pressure 114 to the sheet 202 using the roller 102.

[0089] Now refer to Figure 2 and Figure 3 , in one or more examples, the system 100 includes a tool 106. The tool 106 includes a tool surface 108. With the roller 102 in contact with the sheet surface 210 and applying the compaction pressure 114, the movement of the roller 102 across the sheet 202 causes the sheet 202 to conform to the tool surface 108.

[0090] Now refer to Figure 2 and Figure 3 , in one or more examples, the tool surface 108 includes a profile 158. In one or more examples, the profile 158 is a complex profile, where the tool surface 108 has curvature in multiple axial directions.

[0091] Now refer to Figure 2 and Figure 3 , in one or more examples, at least a portion of the compaction surface 104 is formed by the tool surface 108.

[0092] Now refer toFigure 2 and Figure 3 In one or more examples, at least a portion of the compacted surface 104 is formed by a previous laminate surface 210 of a previous laminate 110 of the ceramic composite material 200 positioned on the tool 106.

[0093] Referring Figure 2 In one or more examples, the covering 126 includes foam 128. In one or more examples, the covering 126 includes a closed-cell foam 130. In one or more examples, the covering 126 includes an inflatable airbag 132. In one or more examples, the covering 126 is impermeable.

[0094] Referring Figure 2 In one or more examples, the covering 126 includes a Shore A hardness between about 1 and 10. In one or more examples, the covering 126 includes a Shore A hardness between about 3 and 7. In one or more examples, the covering 126 includes a Shore A hardness of about 5.

[0095] Referring Figure 2 In one or more examples, the covering 126 includes at least one of silicone, urethane, polyurethane, latex, etc.

[0096] Referring Figure 2 、 Figure 6 and Figure 7 In one or more examples, the covering 126 includes a covering material 134. In one or more examples, the covering material 134 is selected such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI). In one or more examples, the covering material 134 is selected such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 20.6843 kPa (3 PSI). In one or more examples, the covering material 134 is selected such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 6.8948 kPa (1 PSI).

[0097] Referring Figure 2 and Figures 5 to 7 In one or more examples, a pressure sensor film 144 is used to verify the covering material 134. In these examples, the pressure sensor film 144 generates pressure data 166 that is transmitted to a computer 168 such as a feedback controller 152 for analysis.

[0098] Referring Figure 2 and Figures 6 to 8, in one or more examples, system 100 includes a pressure sensor diaphragm 144. The pressure sensor diaphragm 144 is configured to measure the compaction pressure 114. In these examples, the pressure sensor diaphragm 144 generates pressure data 166, which is transmitted to a computer 168 such as a feedback controller 152 for analyzing and adjusting the contact interface 116 as needed or desired to achieve and / or maintain uniformity.

[0099] Referring to Figure 2 , in one or more examples, computer 168 includes any suitable data processing system 170 configured to receive, analyze, generate, and / or transmit various types of data, information, and / or signals, e.g., for controlling or otherwise providing instructions for the operating components of system 100 and / or for performing the steps of method 1000. In one or more examples, data processing system 170 includes at least one processor 172 and a memory 174 that stores instructions (e.g., program code 176) that, when executed, cause processor 172 to initiate the execution of one or more operational steps of method 1000 or cause system 100 to perform one or more operational steps of method 1000. In one or more examples, processor 172 is configured to read from and write to memory 174. In one or more examples, processor 172 is configured to receive input commands and provide output commands. In one or more examples, e.g., processor 172 is a multi-functional processor such as a central processing unit. In one or more examples, the functions of processor 172 are performed by a local processor, a remote processor, or a combination thereof. In one or more examples, processor 172 is implemented separately in hardware (e.g., circuitry, microprocessor, etc.), or has certain aspects in software including separate firmware, or can be a combination of hardware and software (including firmware). In one or more examples, processor 172 can be implemented using instructions capable of implementing hardware functions, e.g., by using executable computer program instructions (e.g., program code 176) in a general-purpose or special-purpose processing unit stored in memory 174 or other computer-readable storage medium (e.g., disk, memory, etc.) executed by processor 172. Memory 174 stores a computer program (e.g., program code 176) that includes computer program instructions that control the operation of processor 172 when loaded into the processing circuitry. The computer program instructions provide the logic and routines that enable processor 172 to execute Figure 2Method 1000 as illustrated therein. By reading the memory 174, the processing circuitry is capable of loading and executing the program code 176. The program code 176 can reach the processor 172 via any suitable delivery mechanism. For example, the delivery mechanism can be a non-transitory computer-readable storage medium, a computer program product, a storage device, a recording medium such as a compact disc read-only memory (CD-ROM) or a digital versatile disc (DVD), an article of manufacture tangibly embodying a computer program. The delivery mechanism can be a signal configured to reliably transmit a computer program. The device can propagate or transmit the computer program as a computer data signal. Although the memory 174 is illustrated as a single component, it can be implemented as one or more separate components, some or all of which can be integrated / removable and / or can provide permanent / semi-permanent / dynamic / cache storage. References to "computer-readable storage medium", "computer program product", "tangibly embodied computer program", etc. or "controller", "computer", "processor", etc. should be understood to include not only computers having different architectures (such as single / multiprocessor architectures and sequential (von Neumann) / parallel architectures), but also dedicated circuits such as field programmable gate arrays (FPGA), application specific integrated circuits (ASIC), signal processing devices, and other processing circuitry. For example, references to computer programs, instructions, code, etc. should be understood to include software or firmware for programmable processors, such as programmable content of a hardware device, whether instructions for a processor or configuration settings for a fixed function device, gate array, or programmable logic device, etc.

[0100] Now refer to Figure 10 and Figure 11 The examples of method 1000 and system 100 described herein may be related to Figure 10 the aerospace manufacturing and service method 1100 shown in the flowchart of Figure 11 and the aircraft 1200 schematically illustrated therein, or used in the context of the aerospace manufacturing and service method 1100 and the aircraft 1200. As an example, the aircraft 1200 and / or the manufacturing and service method 1100 can include or utilize components made of ceramic matrix composites, which are compacted using the system 100 and / or according to the method 1000.

[0101] Refer to Figure 11, which illustrates an example of an aircraft 1200. The aircraft 1200 can be any aerospace vehicle or platform. In one or more examples, the aircraft 1200 includes a fuselage 1202 having an interior 1206. The aircraft 1200 includes a plurality of on-board systems 1204 (e.g., advanced systems). Examples of the on-board systems 1204 of the aircraft 1200 include a propulsion system 1208, a hydraulic system 1212, an electrical system 1210, and an environmental system 1214. In other examples, the on-board systems 1204 further include one or more control systems coupled to the fuselage 1202 of the aircraft 1200. In other examples, the on-board systems 1204 further include one or more other systems, such as but not limited to communication systems, avionics systems, software distribution systems, network communication systems, passenger information / entertainment systems, guidance systems, radar systems, weapon systems, etc. The aircraft 1200 can have any number of components made of ceramic matrix composites, which are compacted using the system 100 and / or according to the method 1000.

[0102] Referring to Figure 10 , during the pre-production process of the aircraft 1200, the manufacturing and service method 1100 includes the specification and design of the aircraft 1200 (block 1102) and material procurement (block 1104). During the production process of the aircraft 1200, component and sub-assembly manufacturing of the aircraft 1200 (block 1106) and system integration (block 1108) are performed. Thereafter, the aircraft 1200 is put into service (block 1112) through certification and delivery (block 1110). Routine maintenance and servicing (block 1114) includes modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft 1200.

[0103] Figure 10 Each of the processes of the manufacturing and service method 1100 illustrated in can be performed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator can include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party can include, but is not limited to, any number of suppliers, subcontractors, and vendors; an operator can be an airline, a leasing company, a military entity, a service organization, etc.

[0104] According to an embodiment of the present application (see the accompanying drawings), a method 1000 for compacting a ceramic composite material 200 including a ceramic reinforcement 204 and a ceramic matrix 208 includes the following steps: positioning a roller 102 to contact a laminate surface 210 of a laminate 202 of the ceramic composite material 200, wherein the laminate 202 is positioned on a compacting surface 104; applying a compaction pressure 114 to the laminate 202 using the roller 102 such that the compaction pressure 114 is distributed substantially uniformly over the laminate 102; and moving the roller 102 across the laminate 202 while the roller 102 is in contact with the laminate surface 210 and applying the compaction pressure 114, thereby conforming the laminate 202 of the ceramic composite material 200 to the compacting surface 104.

[0105] Optionally, the method further includes selecting a magnitude 122 of the compaction pressure 114, wherein the magnitude 122 of the compaction pressure 114 is selected to conform the ceramic reinforcement 204 of the laminate 202 to a profile 158 of the compacting surface 104 while moving the roller 102 across the laminate 202 and the laminate maintains a desired thickness of the laminate 202. Also optionally, a feedback controller 152 can be used to adjust the magnitude 122 of the compaction pressure 114 while the roller 102 is in contact with the laminate surface 210.

[0106] In the illustrated embodiment, the ceramic reinforcement 204 includes at least one of carbon reinforcement fibers, silicon carbide reinforcement fibers, alumina reinforcement fibers, aluminum-silica reinforcement fibers, aluminum nitride reinforcement fibers, silicon oxynitride reinforcement fibers, mullite reinforcement fibers, silica / quartz reinforcement fibers, basalt reinforcement fibers, and zirconia reinforcement fibers. In combination with this particular ceramic reinforcement 204 or as a separate aspect, the ceramic matrix 208 can include at least one of a carbon matrix, a silicon carbide matrix, an alumina matrix, an alumina-silica matrix, an aluminum nitride matrix, a silicon nitride matrix, a mullite matrix, a geopolymer matrix, and a zirconia matrix.

[0107] Preferably, the compaction pressure 114 is substantially uniform along a contact interface 116 between the roller 102 and the laminate 202 such that a variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI).

[0108] In addition, the roller 102 preferably includes a core 124 and a covering 126 surrounding the core 124. Optionally, the method further includes the step of selecting a covering material 134 for the covering 126, wherein the covering material 134 is selected such that when the roller 102 is moved across the laminate 202, the compaction pressure 114 is uniform along the contact interface 116 between the roller 102 and the laminate 202. In this method, the covering material 134 is preferably selected such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI). Optionally, in this method, the step of selecting the covering material 134 includes the steps of: providing a test roller 136 including a test core 138 and a test covering 140 surrounding the test core 138, the test covering 140 including a test covering material 142; positioning the test roller 136 in contact with a pressure sensor film 144; applying the compaction pressure 114 to the pressure sensor film 144 using the test roller 136 while the test roller 136 is in contact with the pressure sensor film 144 and applying the compaction pressure 114; moving the test roller 136 across the pressure sensor film 144; measuring the compaction pressure 114 while the test roller 136 is moved across the pressure sensor film 144; determining whether the compaction pressure 114 is uniform along the test contact interface 146 between the test roller 136 and the pressure sensor film 144 when the test roller 136 is moved across the pressure sensor film 144; and verifying the test covering material 142 when the compaction pressure 114 is uniform along the test contact interface 146 and determining that the compaction pressure 114 is uniform when the variation 118 of the compaction pressure 114 along the test contact interface 146 is less than 34.4748 kPa (5 PSI). Providing the test roller 136 can effectively determine the compaction pressure. Measuring the compaction pressure with such a test roller helps to better understand one or more of material selection, movement speed, compaction pressure, pressure uniformity, etc. This can improve the compaction process. For example, the test roller 13 can be used in combination with the application of the pressure sensor film 144, or can be used without the application of the pressure sensor film 144.

[0109] As a further step, method 1000 may also include the steps of: measuring the compaction pressure 114 while moving the roller 102 across the laminate 202; and adjusting the compaction pressure 114 in response to the measurement when the compaction pressure 114 is non-uniform along the contact interface 116 between the roller 102 and the laminate 204. Optionally, in this method, the step of measuring the compaction pressure 114 includes the steps of: positioning the pressure sensor film 144 in contact with the laminate surface 210 of the laminate 202; positioning the roller 102 in contact with the pressure sensor film 144; applying the compaction pressure 114 to the pressure sensor film 144 using the roller 102 while the roller 102 is in contact with the pressure sensor film 144 and applying the compaction pressure 114; moving the roller 102 across the pressure sensor film 144; measuring the compaction pressure 114 while moving the roller 102 across the pressure sensor film 144; determining whether the compaction pressure 114 is uniform along the contact interface 116 between the roller 102 and the pressure sensor film 144 when the roller is moved across the pressure sensor film 144, and determining that the compaction pressure 114 is uniform when the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI). Measuring the compaction pressure helps to better understand one or more of material selection, movement speed, compaction pressure, pressure uniformity, etc. This can improve the compaction process. The measuring step and / or measuring system can be applied in combination with the use of a test roller or can be applied without the use of a test roller.

[0110] Also as another step, method 1000 may include the additional step of providing a closed-cell foam 130 having a Shore A hardness of approximately 5 for the covering 126 that surrounds the core 124.

[0111] According to an embodiment of the present application (see the accompanying drawings), a system 100 for compacting a ceramic composite material 200 includes a roller 102 that includes a core 124 and a covering 126 that surrounds the core 124, wherein the covering 126 is selected such that the compaction pressure 114 applied to the laminate 202 of the ceramic composite material 200 is uniform along the contact interface 116 between the roller 102 and the sheet 202. Preferably, the system 100 further includes a robotic manipulator 148 having an end effector 150, wherein the roller 102 is coupled to the end effector 150, and the robotic actuator 148 is configured to position the roller 102 in contact with the laminate surface 210 of the laminate 202 of the ceramic composite material 200 that is positioned on the compaction surface 104, and the robotic actuator 148 is configured to: apply the compaction pressure 114 to the laminate 202 using the roller 102 while the roller is in contact with the laminate surface 210 and applying the compaction pressure 114, and the robotic actuator 148 is configured to move the roller 102 across the laminate 202.

[0112] Preferably, the covering 126 includes a covering material 134, and the covering material 134 is rotated such that the variation 118 of the compaction pressure 114 along the contact interface 116 is less than 34.4748 kPa (5 PSI). Optionally, the covering 126 includes one of a foam 128, a closed-cell foam 130, or an inflatable bladder 132. Preferably, the covering 126 includes a Shore A hardness between about 1 and 10, more preferably between about 3 and 7, and most preferably, the covering 126 includes a Shore A hardness of about 5. Optionally, the covering 126 includes at least one of silicone, polyurethane, polyurethane and latex.

[0113] Examples of the method 1000 and system 100 shown and described herein can be used in any one or more stages of the manufacturing and service method 1100 shown in the flowchart illustrated by Figure 10 During an example, during a part of component and sub-component manufacturing (block 1106) and / or system integration (block 1108), components of the aircraft 1200 can be manufactured from ceramic matrix composites compacted using the system 100 and / or according to the method 1000. Additionally, while the aircraft 1200 is being put into service (block 1112), components of the aircraft 1200 can be manufactured from ceramic matrix composites compacted using the system 100 and / or according to the method 1000. Additionally, during system integration (block 1108) and certification and delivery (block 1110), components of the aircraft 1200 can be manufactured from ceramic matrix composites compacted using the system 100 and / or according to the method 1000. Similarly, when the aircraft 1200 is being put into service (block 1112) and during maintenance and servicing (block 1114), components of the aircraft 1200 can be manufactured from ceramic matrix composites compacted using the system 100 and / or according to the method 1000.

[0114] The foregoing detailed description refers to the accompanying drawings that illustrate specific examples described by this disclosure. Other examples with different structures and operations do not depart from the scope of this disclosure. The same reference numerals may refer to the same features, elements, or components in different drawings. Throughout this disclosure, any one of a plurality of items may be referred to individually as an item, and a plurality of items may be collectively referred to as items and may be represented by the same reference numeral. Additionally, as used herein, the word "a" before a feature, element, component, or step should be understood as not excluding a plurality of features, elements, components, or steps, unless such exclusion is explicitly stated.

[0115] Illustrative, non-exhaustive examples of the subject matter in accordance with the present disclosure are provided above, which may or may not be claimed. As used herein, an "example" refers to one or more features, structures, elements, components, characteristics, and / or operational steps described in connection with the example being included in at least one aspect, embodiment, and / or implementation of the subject matter in accordance with the present disclosure. Thus, the phrases "an example", "another example", "one or more examples", and similar language throughout the present disclosure may or may not refer to the same example. Additionally, the subject matter characterizing any one example may or may not include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may or may not be combined with the subject matter characterizing any other example.

[0116] As used herein, a system, apparatus, device, structure, article, element, component, or hardware "configured to" perform a specified function is indeed capable of performing the specified function without any change, rather than merely having the potential to perform the specified function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware "configured to" perform a specified function is selected, created, implemented, used, programmed, and / or designed specifically to perform the specified function. As used herein, "configured to" denotes an existing characteristic of a system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of the present disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as being "adapted to" and / or "operable to" perform that function.

[0117] Unless otherwise specified, the terms "first", "second", "third", etc. as used herein are merely labels and are not intended to impose an order, position, or hierarchical requirement on the items to which these terms refer. Additionally, the mention of a "second" item does not require or preclude the existence of a "first" or lower-numbered item and / or a "third" or higher-numbered item.

[0118] As used herein, when used in conjunction with a list of items, the phrase "at least one" means that different combinations of one or more of the listed items may be used and it may be necessary to have only one of each item in the list. For example, "at least one of item A, item B, and item C" may include, but is not limited to, item A or item A and item B. This example may also include item A, item B, and item C or item B and item C. In other examples, "at least one" may be, for example but not limited to, two of item A, one of item B, and ten of item C; four of item B and seven of item C; and other suitable combinations. As used herein, the terms "and / or" and the " / " symbol include any and all combinations of one or more of the associated listed items.

[0119] For the purposes of this disclosure, the terms "coupled" and like terms refer to two or more elements that are joined, linked, fastened, attached, connected, in communication with, or otherwise associated with each other (e.g., mechanically, electrically, fluidically, optically, electromagnetically). In various examples, these elements may be directly or indirectly associated. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B via another element C. It should be understood that not all associations between the disclosed elements need to be shown. Thus, there may also be couplings other than those shown in the figures.

[0120] As used herein, the term "approximate" means or represents a condition that is close to but not exactly the stated condition and that still enables the performance of the desired function or the achievement of the desired result. As an example, the term "approximate" means a condition within an acceptable predetermined tolerance or accuracy range, such as a condition within 10% of the stated condition. However, the term "approximate" does not exclude a condition that is exactly the same as the stated condition. As used herein, the term "substantially" means a state that is essentially the performance of the desired function or the achievement of the desired result.

[0121] The above-mentioned Figures 2 to 9 and Figure 11 may represent its functional elements, features, or components and do not necessarily imply any particular structure. Thus, the shown structure may be modified, added to, and / or omitted. Additionally, those skilled in the art will understand that not all of the Figures 2 to 9 and Figure 11 elements, features, and / or components described and illustrated above need to be included in each example, and not all of the elements and / or components described herein must be described in each illustrative example. Thus, Figures 2 to 9 and Figure 11 some of the elements, features, and / or components described and illustrated in Figures 2 to 9 , Figure 11 , other figures, and / or other features described and illustrated in the accompanying disclosure may be combined in various ways without the need to include Figures 2 to 9 and Figure 11 even if such combinations are not explicitly shown herein. Similarly, additional features not limited to the presented examples may be combined with some or all of the features shown and described herein. Unless otherwise explicitly stated, the schematic diagrams of the examples illustrated in the above Figures 2 to 9 and Figure 11Elements, features, and / or components for similar or at least substantially similar purposes are marked with the same reference numerals, and these elements, features, and / or components may not be discussed in detail herein with reference to Figures 2 to 9 and Figure 11 each. Similarly, all elements, features, and / or components may not be labeled in Figures 2 to 9 and Figure 11 one by one, but for the sake of consistency, the associated reference numerals may be used herein.

[0122] In the above-mentioned Figure 1 and Figure 10 the boxes may represent operations, steps, and / or parts thereof, and the lines connecting the boxes do not imply any particular order or dependency of the operations or parts thereof. It should be understood that not all dependencies between the various disclosed operations need to be represented. Figure 1 and Figure 10 Also, the accompanying disclosure that describes the operations of the methods disclosed herein should not be construed as necessarily determining the order in which the operations are to be performed. Instead, although an illustrative order is indicated, it should be understood that the order of the operations can be modified when appropriate. Thus, the operations shown can be modified, added, and / or omitted, and certain operations can be performed in a different order or simultaneously. In addition, those skilled in the art will understand that not all of the described operations need to be performed.

[0123] Furthermore, this application includes embodiments according to the following examples:

[0124] 1. A method (1000) for compacting a ceramic composite material (200), the ceramic composite material comprising a ceramic reinforcement (204) and a ceramic matrix (208), the method (1000) comprising the following steps:

[0125] Positioning a roller (102) in contact with a laminate surface (210) of a laminate (202) of the ceramic composite material (200), wherein the laminate (202) is positioned on a compaction surface (104);

[0126] Applying a compaction pressure (114) to the laminate (202) using the roller (102) such that the compaction pressure (112) is distributed substantially uniformly over the laminate (202); and

[0127] Moving the roller (102) across the laminate (202) while the roller (102) is in contact with the laminate surface (210) and applying the compaction pressure (114) to conform the laminate (202) of the ceramic composite material (200) to the compaction surface (104).

[0128] 2. The method (1000) according to Example 1, the method further comprising: selecting a magnitude (122) of the compaction pressure (114), wherein the magnitude (122) of the compaction pressure (114) is selected to conform the ceramic reinforcement (204) of the laminate (202) to a profile (158) of the compaction surface (104) while moving the roller (102) across the laminate (202), and maintaining a desired thickness of the laminate (202).

[0129] 3. The method (1000) according to Example 2, the method further comprising: using a feedback controller (152) to adjust the magnitude (122) of the compaction pressure (114) when the roller (102) is in contact with the laminate surface (210).

[0130] 4. The method (1000) according to Example 1, wherein:

[0131] the ceramic reinforcement (204) comprises at least one of carbon reinforced fibers, silicon carbide reinforced fibers, alumina reinforced fibers, alumina-silica reinforced fibers, aluminum nitride reinforced fibers, silicon oxynitride reinforced fibers, mullite reinforced fibers, silica / quartz reinforced fibers, basalt reinforced fibers, and zirconia reinforced fibers; and

[0132] the ceramic matrix (208) comprises at least one of a carbon matrix, a silicon carbide matrix, an alumina matrix, an alumina-silica matrix, an aluminum nitride matrix, a silicon nitride matrix, a mullite matrix, a geopolymer matrix, and a zirconia matrix.

[0133] 5. The method (1000) according to Example 1, wherein the compaction pressure (114) is approximately uniform along a contact interface (116) between the roller (102) and the laminate (202), such that a variation (118) of the compaction pressure (114) along the contact interface (116) is less than 5 PSI.

[0134] 6. The method (1000) according to Example 1, the method further comprising providing the roller (102), wherein the roller comprises:

[0135] a core (124); and

[0136] a covering (106) surrounding the core (124).

[0137] 7. The method (1000) according to Example 6, the method further comprising the step of selecting a covering material (134) for the covering (126), wherein the covering material (134) is selected such that when the roller (102) is moved across the laminate (202), the compaction pressure (114) is uniform along the contact interface (116) between the roller (102) and the laminate (202).

[0138] 8. The method (1000) according to Example 7, wherein the covering material (134) is selected such that the variation (118) of the compaction pressure (114) along the contact interface (116) is less than 5 PSI.

[0139] 9. The method (1000) according to Example 7, wherein:

[0140] The step of selecting the covering material (134) comprises:

[0141] Providing a test roller (136), the test roller including a test core (138) and a test covering (140) surrounding the test core (138), the test covering (140) including a test covering material (142);

[0142] Positioning the test roller (136) in contact with a pressure sensor film (144);

[0143] Using the test roller (136) to apply the compaction pressure (114) to the pressure sensor film (144);

[0144] While the test roller (136) is in contact with the pressure sensor film (144) and applying the compaction pressure (114), moving the test roller (136) across the pressure sensor film (144);

[0145] While moving the test roller (136) across the pressure sensor film (144), measuring the compaction pressure (114);

[0146] Determining whether the compaction pressure (114) is uniform along the test contact interface (146) between the test roller (136) and the pressure sensor film (144) when the test roller (136) is moved across the pressure sensor film (144); and

[0147] When the compaction pressure (114) is uniform along the test contact interface (146), verifying the test covering material (142); and

[0148] When the variation (118) of the compaction pressure (114) along the test contact interface (146) is less than 5 PSI, the compaction pressure (14) is determined to be uniform.

[0149] 10. The method (1000) according to Example 1, the method further comprising:

[0150] Measuring the compaction pressure (114) while moving the roller (102) across the laminate (202); and

[0151] When the compaction pressure (114) is non-uniform along the contact interface (116) between the roller (102) and the laminate (202), adjusting the compaction pressure (114) in response to the measurement.

[0152] 11. The method (1000) according to Example 10, wherein,

[0153] The step of measuring the compaction pressure (114) includes:

[0154] Positioning a pressure sensor film (144) in contact with the laminate surface (210) of the laminate (202);

[0155] Positioning the roller (102) in contact with the pressure sensor film (144);

[0156] Applying the compaction pressure (114) to the pressure sensor film (144) using the roller (102);

[0157] While the roller (102) is in contact with the pressure sensor film (144) and applying the compaction pressure (114), moving the roller (102) across the pressure sensor film (144);

[0158] Measuring the compaction pressure (114) while moving the roller (102) across the pressure sensor film (144); and

[0159] Determining whether the compaction pressure (114) is uniform along the contact interface (116) between the roller (102) and the pressure sensor film (144) when the roller (102) is moved across the pressure sensor film (144); and

[0160] When the variation (118) of the compaction pressure (114) along the contact interface (116) is less than 5 PSI, the compaction pressure (114) is determined to be uniform.

[0161] 12. A method (1000) for compacting a ceramic composite (200), the method (100) comprising the steps of:

[0162] Provide a roller (112), wherein the roller (112) comprises:

[0163] A core (124); and

[0164] A covering (106), the covering surrounding the core (124) and comprising a closed-cell foam (130) having a Shore A hardness of about 5,

[0165] Position a laminate (202) of the ceramic composite material (200) on a compaction surface (104), wherein the laminate (202) of the ceramic composite material comprises a ceramic reinforcement (204) and a ceramic matrix (208);

[0166] Position the roller (102) in contact with a laminate surface (210) of the laminate (202);

[0167] Apply a compaction pressure (114) to the laminate (202) using the roller (102), wherein the compaction pressure (112) is substantially uniform along a contact interface (116) between the roller (102) and the laminate (202);

[0168] With the roller (102) in contact with the laminate surface (210) and applying the compaction pressure (114), move the roller (102) across the laminate (202) to conform the laminate (202) to the compaction surface (104); and

[0169] With the roller (102) in contact with the laminate surface (210), adjust the compaction pressure (114) using a feedback controller (152) while moving the roller (102).

[0170] 13. A system (100) for compacting a ceramic composite material (200), the system (100) comprising:

[0171] A roller (102), the roller comprising:

[0172] A core (124); and

[0173] A covering (126), the covering surrounding the core (124),

[0174] wherein the covering (126) is selected such that the compaction pressure (114) applied to a laminate (202) of the ceramic composite material (200) is uniform along a contact interface (116) between the roller (102) and the laminate (202).

[0175] 14. The system (100) according to Example 13, the system further includes a robotic manipulator (148) having an end effector (150), wherein:

[0176] The roller (102) is coupled to the end effector (150);

[0177] The robotic manipulator (148) positions the roller (102) to contact a ply surface (210) of the ply (202) of the ceramic composite material (200) that is positioned on the compaction surface (104);

[0178] The robotic manipulator (148) applies the compaction pressure (114) to the ply (202) using the roller (102); and

[0179] With the roller (102) in contact with the ply surface (210) and applying the compaction pressure (114), the robotic manipulator (148) moves the roller (102) across the ply (202).

[0180] 15. The system (100) according to Example 13, wherein:

[0181] The covering (126) includes a covering material (134); and

[0182] The covering material (134) is selected such that the variation (118) of the compaction pressure (114) along the contact interface (116) is less than 5 PSI.

[0183] 16. The system (100) according to Example 13, wherein the covering (126) includes one of a foam (128), a closed-cell foam (130), or an inflatable bladder (132).

[0184] 17. The system (100) according to Example 13, wherein the covering (126) includes a Shore A hardness between about 1 and 10.

[0185] 18. The system (100) according to Example 17, wherein the covering (126) includes a closed-cell foam (130) and a Shore A hardness between about 3 and 7.

[0186] 19. The system (100) according to Example 18, wherein the covering (126) includes a Shore A hardness of about 5.

[0187] 20. The system (100) according to Example 13, wherein the covering (126) includes at least one of silicone, urethane, polyurethane, and latex.

[0188] Moreover, references throughout this specification to features, advantages, or similar language do not imply that all features and advantages that can be realized by the examples disclosed herein should be present in or should be realized by any single example. Rather, the language referring to features and advantages is understood to mean that a particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, the discussions of the features, advantages, and similar language used herein may, but do not necessarily, refer to the same example.

[0189] The features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. Those skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other instances, additional features and advantages may be recognized that are not present in some examples but are present in others. Moreover, although various examples of systems 100 and methods 1000 have been shown and described, modifications may be made by those skilled in the art after reading the specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A method (1000) for compacting a ceramic composite material (200), the ceramic composite material comprising a ceramic reinforcement (204) and a ceramic matrix (208), the method (1000) comprising the following steps: positioning a roller (102) in contact with a ply surface (210) of a ply (202) of the ceramic composite material (200), wherein the ply (202) is positioned on a compacting surface (104); applying a compaction pressure (114) to the ply (202) using the roller (102) such that the compaction pressure (114) is substantially evenly distributed across the ply (202); and With the roller (102) in contact with the ply surface (210) and the compaction pressure (114) applied, moving the roller (102) across the ply (202) to conform the ply (202) of the ceramic composite material (200) to the compaction surface (104), The method further comprises providing the roller (112), wherein the roller (112) comprises: core(124); and a covering (106) surrounding the core (124), The method further includes the step of selecting a covering material (134) for the covering (126), wherein the covering material (132) is selected such that when the roller (102) is moved across the ply (202), the compaction pressure (114) is uniform along a contact interface (116) between the roller (102) and the ply (202), wherein: The step of selecting the covering material (134) comprises: providing a test roller (136), the test roller comprising a test core (138) and a test cover (140) surrounding the test core (138), the test cover (140) comprising a test cover material (142); positioning the test roller (136) in contact with the pressure sensor membrane (144); applying the compaction pressure (114) to the pressure sensor membrane (144) using the test roller (136); moving the test roller (136) across the pressure sensor membrane (144) with the test roller (136) in contact with the pressure sensor membrane (144) and applying the compaction pressure (114); measuring the compaction pressure (114) while moving the test roller (136) across the pressure sensor membrane (144); determining whether the compaction pressure (114) is uniform along a test contact interface (146) between the test roller (136) and the pressure sensor membrane (144) when the test roller (136) is moved across the pressure sensor membrane (144); and verifying the test cover material (142) when the compaction pressure (114) is uniform along the test contact interface (146); and The compaction pressure (14) is determined to be uniform when the variation (118) of the compaction pressure (114) along the test contact interface (146) is less than 34.4748 kPa (5 PSI).

2. The method (1000) according to claim 1, further comprising: The magnitude (122) of the compaction pressure (114) is selected, wherein the magnitude (122) of the compaction pressure (114) is selected to cause the ceramic reinforcement (204) of the ply (202) to conform to the contour (158) of the compaction surface (104) while moving the roller (102) across the ply (202) and the ply maintains a desired thickness of the ply (202).

3. The method (1000) according to claim 1 or 2, wherein: The ceramic reinforcement (204) comprises at least one of carbon reinforcement fiber, silicon carbide reinforcement fiber, aluminum oxide reinforcement fiber, aluminum oxide-silicon dioxide reinforcement fiber, aluminum nitride reinforcement fiber, silicon oxynitride reinforcement fiber, mullite reinforcement fiber, silicon dioxide / quartz reinforcement fiber, basalt reinforcement fiber and zirconium oxide reinforcement fiber; and The ceramic matrix (208) includes at least one of a carbon matrix, a silicon carbide matrix, an aluminum oxide matrix, an aluminum oxide-silicon dioxide matrix, an aluminum nitride matrix, a silicon nitride matrix, a mullite matrix, a geopolymer matrix, and a zirconium oxide matrix.

4. The method (1000) according to any one of the preceding claims, wherein: The compaction pressure (114) is approximately uniform along a contact interface (116) between the roller (102) and the ply (202), such that a variation (118) of the compaction pressure (114) along the contact interface (116) is less than 34.4748 kPa (5 PSI).

5. The method (1000) according to any one of the preceding claims, wherein: The cover material (134) is selected such that a variation (118) of the compaction pressure (114) along the contact interface (116) is less than 34.4748 kPa (5 PSI).

6. The method (1000) according to any one of the preceding claims, further comprising: measuring the compaction pressure (114) while moving the roller (102) across the ply (202); and When the compaction pressure (114) is not uniform along a contact interface (116) between the roller (102) and the ply (202), the compaction pressure (114) is adjusted in response to the measurement.

7. A system (100) for compacting a ceramic composite material (200), the system (100) comprising: A roller (102), the roller comprising: core(124); and a covering (126) surrounding the core (124), wherein the cover (126) is selected so that the compaction pressure (114) when applied to the ply (202) of the ceramic composite material (200) is uniform along the contact interface (116) between the roller (102) and the ply (202), The system also includes a test roller (136), the test roller including a test core (138) and a test cover (140) surrounding the test core (138), the test cover (140) including a test cover material (142), wherein the test roller is configured to be positioned in contact with the pressure sensor membrane (144), and wherein the test roller is configured to apply the compaction pressure (114) to the pressure sensor membrane (144) while moving the test roller (136) across the pressure sensor membrane (144).

8. The system (100) according to claim 7, wherein: The covering (126) includes one of a foam (128), a closed cell foam (130), or an inflatable bladder (132).

9. The system (100) according to claim 7 or 8, wherein: The cover (126) comprises a Shore A hardness between about 1 and 10, preferably between about 3 and 7, and more preferably about 5.

10. The system (100) according to any one of claims 7 to 9, wherein: The covering (126) includes at least one of silicone, urethane, polyurethane and latex.

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