Ceramic composite component

Abstract

A ceramic composite component includes a ceramic core structure having a plurality of hollow cells defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure. A ceramic matrix composite (CMC) structure is coupled to the ceramic core structure and includes a plurality of CMC layers. The CMC structure is defined by a first side of the CMC structure and a second side of the CMC structure, the second side of the CMC structure being opposite the first side of the CMC structure. The first CMC panel is bonded to the first side of the ceramic core structure and the first side of the CMC structure. A second CMC panel is bonded to a second side of the ceramic core structure and a second side of the CMC structure.

Description

Technical Field

[0001] The subject matter generally relates to components and processes for manufacturing components, or more specifically to ceramic composite components. Background Art

[0002] Silicon carbide (SiC)-based ceramic matrix composite (CMC) materials have been proposed as materials for certain components of various types of aerospace structures. A variety of methods for manufacturing SiC-based components are known, including melt infiltration (MI), chemical vapor infiltration (CVI), and polymer infiltration pyrolysis (PIP) methods. Although these manufacturing techniques are quite different from each other, each technique involves the use of manual layup and tools or dies to produce near-net shape parts by methods that include applying heat at various stages of the methods. Brief Description of the Drawings

[0003] A complete and enabling disclosure of the present disclosure, including its best mode, for a person of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings.

[0004] Figure 1 is a top view of an aerospace structure according to various exemplary embodiments of the present disclosure.

[0005] Figure 2 is Figure 1 a starboard view of an exemplary aerospace structure.

[0006] Figure 3 is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the present disclosure.

[0007] Figure 4 is a schematic plan view of an exemplary ceramic composite component according to an embodiment of the present disclosure.

[0008] Figure 5 is along Figure 4 line 5-5 of Figure 4 an exemplary ceramic composite component according to an embodiment of the present disclosure.

[0009] Figure 6 is according to an embodiment of the present disclosure Figure 4 a schematic plan view of an exemplary ceramic core structure of an exemplary ceramic composite component.

[0010] Figure 7 is according to an embodiment of the present disclosure Figure 6 a schematic side view of an exemplary ceramic core structure.

[0011] Figure 8 is along Figure 6 line 8-8 of Figure 6Schematic partial cross-sectional view of an exemplary ceramic core structure.

[0012] Figure 9 is a schematic partial cross-sectional view of an exemplary ceramic core structure taken along Figure 7 line 9-9 of Figure 7 the exemplary ceramic core structure.

[0013] Figure 10 is a schematic view of an exemplary CMC structure of an exemplary ceramic composite component according to an embodiment of the present disclosure and usable for Figure 4 the exemplary ceramic composite component.

[0014] Figure 11 is a schematic view of another exemplary CMC structure of an exemplary ceramic composite component according to an embodiment of the present disclosure and usable for Figure 4 the exemplary ceramic composite component.

[0015] Figure 12 is an enlarged cross-sectional view of a part of an exemplary ceramic composite component according to an embodiment of the present disclosure. Figure 5 the exemplary ceramic composite component.

[0016] Figure 13 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0017] Figure 14 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0018] Figure 15 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0019] Figure 16 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0020] Figure 17 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0021] Figure 18 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0022] Figure 19 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0023] Figure 20 is a schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0024] Figure 21Schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0025] Figure 22 Schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0026] Figure 23 Schematic cross-sectional view of another exemplary ceramic composite component according to an embodiment of the present disclosure.

[0027] Figure 24 Schematic plan view of an exemplary ceramic composite component according to another embodiment of the present disclosure.

[0028] Figure 25 Is along according to an embodiment of the present disclosure Figure 24 Intercepted along line 25-25 of Figure 24 Schematic cross-sectional view of an exemplary ceramic composite component.

[0029] Figure 26 Flowchart of an exemplary method for forming a ceramic composite component according to the present disclosure.

[0030] Figure 27 Flowchart of another exemplary method for forming a ceramic composite component according to the present disclosure.

[0031] Figure 28 Flowchart of another exemplary method for forming a ceramic composite component according to the present disclosure. Detailed Description

[0032] Reference will now be made in detail to the current embodiments of the present disclosure, one or more examples of which are shown in the accompanying drawings. The detailed description uses numerical and alphabetical labels to refer to features in the drawings. Similar or like labels have been used in the drawings and the description to refer to similar or like parts of the present disclosure.

[0033] As used herein, the terms "first", "second", and "third" may be used interchangeably to distinguish one component from another and are not intended to denote the position or importance of the individual components.

[0034] The terms "front" and "rear" refer to relative positions within an aircraft or vehicle and refer to the normal operating attitude of the aircraft or vehicle. For example, for an aircraft, the front refers to the position closer to the nose of the aircraft, and the rear refers to the position closer to the tail of the aircraft.

[0035] The terms "upstream" and "downstream" refer to the relative direction with respect to fluid flow. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction towards which the fluid flows.

[0036] Unless otherwise specified herein, the terms "coupled", "fixed", "attached", etc. refer to both direct coupling, fixing or attachment and indirect coupling, fixing or attachment through one or more intermediate components or features.

[0037] Unless the context clearly dictates otherwise, the singular forms "a", "an" and "the" include plural referents.

[0038] This disclosure uses common chemical abbreviations for chemical elements to discuss chemical elements, such as those common in the periodic table. For example, hydrogen is represented by its common chemical abbreviation H; helium is represented by its common chemical abbreviation He; and so on.

[0039] As used herein, a ceramic matrix composite or "CMC" refers to a class of materials that includes a reinforcement (e.g., reinforcing fibers) surrounded by a ceramic matrix phase. Generally, the reinforcing fibers provide structural integrity to the ceramic matrix. For example, in an exemplary embodiment, a fiber bundle (which may include a ceramic refractory coating) is formed into a reinforcing tape, such as a unidirectional reinforcing tape. Multiple tapes can be laid together (e.g., as layers) to form a preform component (e.g., to form a ceramic matrix composite structure 300). The fiber bundle can be impregnated with a slurry composition either before forming the preform (e.g., a prepreg layer) or after forming the preform. The preform can then undergo a heat treatment, such as curing or burnout, to produce a high-carbon residue in the preform, and subsequently undergo a chemical treatment, such as melt infiltration with silicon, to obtain a component formed of a CMC material having a desired chemical composition. In other embodiments, the CMC material can be formed as, for example, a carbon fiber cloth rather than a tape. Some examples of the matrix material of the CMC can include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) can also be included in the CMC matrix.

[0040] Some examples of the reinforcing fibers of the CMC can include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates such as mullite, or mixtures thereof), or mixtures thereof.

[0041] Typically, a particular CMC can be referred to by the combination of its fiber type / matrix type. For example, C / SiC represents carbon fiber reinforced silicon carbide; SiC / SiC represents silicon carbide fiber reinforced silicon carbide, SiC / SiN represents silicon carbide fiber reinforced silicon nitride; SiC / SiC-SiN represents silicon carbide fiber reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, the CMC can be composed of a matrix and reinforcing fibers, which include oxide-based materials such as alumina (A12O3), silica (SiO2), aluminosilicates, and mixtures thereof. The aluminosilicates can include crystalline materials such as mullite (3A12O3 2SiO2) and vitreous aluminosilicates.

[0042] In certain embodiments, the reinforcing fibers can be bundled and / or coated before being incorporated into the matrix. For example, fiber bundles can be formed into reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes can be laid together to form a preform component. The fiber bundles can be impregnated with a slurry composition either before or after forming the preform. The preform can then undergo heat treatment, such as curing or burnout to produce a high-carbon residue in the preform, and subsequent chemical treatment, such as melt infiltration with silicon, to obtain a component formed of a CMC material having a desired chemical composition.

[0043] Such materials, as well as certain monolithic ceramics (i.e., ceramic materials without reinforcing materials), are particularly suitable for high-temperature applications. In addition, these ceramic materials are lightweight compared to superalloys but can still provide strength and durability to the components made from them. Therefore, such materials are currently being considered for use in many gas turbine components and other aerospace propulsion system and vehicle structure components used in their high-temperature sections, such as airfoils (e.g., turbines and blades), burners, shrouds, and other similar components, nozzles, transition ducts, thermal protection systems (TPS), aerodynamic control surfaces, and leading edges, which would benefit from the lighter weight and higher temperature capabilities that these materials can provide.

[0044] In some embodiments, the present disclosure includes composite panels or components having a plurality of “internal structures” such as hollow cells, channels, struts, lattice structures, cavities, and other structural and / or functional elements. While ceramic composites provide good toughness, high thermal insulation, high temperature strength, and chemical stability in a wide range of operating environments, the raw materials and processing techniques can be expensive. Current structures capable of withstanding extreme operating conditions may be bulky, expensive, or have a short lifespan. Accordingly, lighter, stronger, and more cost-effective structures are highly desirable in the art and enable a wider range of applications. Composite panels having an internal honeycomb structure (such as a honeycomb or similar cell configuration) can provide similar properties while reducing the weight of the component, particularly the amount of CMC material used in the component. However, the relatively thin walls of the core structure provide a limited bonding area to connect the core structure to one or more panels.

[0045] In an exemplary embodiment, the present disclosure provides a flexible matrix material for bonding various components together. The flexible matrix material can include a reinforcing material, such as a material similar to the materials in adjacent components, to provide similar and compatible properties throughout the composite panel or structure. Additionally, the flexible application of the flexible matrix material can provide enhanced bonding capabilities between the core structure and the composite panel or composite backplane by accommodating dimensional mismatches between the individual components.

[0046] In the present disclosure, when a layer is described as being “on” or “above” another layer or substrate, it is understood that these layers can be in direct contact with each other, or there can be another layer or feature between the layers, unless otherwise explicitly stated. Thus, these terms only describe the relative position between the layers and do not necessarily mean “on top of” as the relative position above or below depends on the orientation of the device relative to the viewer.

[0047] As used herein, the term “adjacent” when used in reference to two walls and / or surfaces means that the two walls and / or surfaces are in contact with each other, or the two walls and / or surfaces are separated only by one or more non-structural layers and the two walls and / or surfaces are in a series contact relationship with the one or more non-structural layers (i.e., the first wall / surface contacts the one or more non-structural layers and the one or more non-structural layers contact the second wall / surface).

[0048] As used herein, the terms “integral,” “monolithic,” or “one-piece” used to describe a structure refer to a structure formed integrally from a continuous material or group of materials without seams, connection joints, etc. The integral, monolithic structures described herein can be formed by additive manufacturing to have the described structure.

[0049] As used herein, the term "additive manufacturing" generally refers to manufacturing techniques in which components are fabricated in a layer-by-layer manner. Exemplary additive manufacturing machines can be configured to utilize any suitable additive manufacturing technique. Additive manufacturing machines can utilize additive manufacturing techniques including powder bed fusion (PBF) techniques, such as direct metal laser melting (DMLM) techniques, selective laser melting (SLM) techniques, direct metal laser sintering (DMLS) techniques, or selective laser sintering (SLS) techniques. In an exemplary PBF technique, thin layers of powder material are sequentially applied to a build plane and then selectively melted or fused together in a layer-by-layer manner to form one or more three-dimensional objects. Additively manufactured objects are typically monolithic in nature and may have various integral sub-components.

[0050] Additionally or alternatively, suitable additive manufacturing techniques can include, for example, binder jetting techniques, fused deposition modeling (FDM) techniques, direct energy deposition (DED) techniques, laser engineered net shaping (LENS) techniques, laser net shaping manufacturing (LNSM) techniques, direct metal deposition (DMD) techniques, digital light processing (DLP) techniques, and other additive manufacturing techniques that utilize an energy beam or other energy source to cure additive manufacturing materials (such as powder materials). In fact, any suitable additive manufacturing modality can be used in conjunction with the presently disclosed subject matter.

[0051] Additive manufacturing techniques can generally be described as manufacturing an object by building the object point-by-point, line-by-line, layer-by-layer, typically in a vertical direction. Other manufacturing methods are conceivable and within the scope of the present disclosure. For example, although the discussion herein relates to adding materials to form successive layers, the presently disclosed subject matter can be practiced using any additive manufacturing technique or other manufacturing technique, including layer addition processes, layer subtraction processes, or hybrid processes.

[0052] The additive manufacturing processes described herein can be used to form components using any suitable material. For example, the material can be a metal, ceramic, polymer, epoxy, photopolymer resin, plastic, or any other suitable material, which can be in a solid, powder, sheet material, wire, or any other suitable form, or a combination thereof. Additionally, or in the alternative, exemplary materials can include metals, ceramics, or binders, and combinations thereof. Exemplary ceramics can include ultra-high temperature ceramics, or precursors of ultra-high temperature ceramics, such as polymer precursors. Each successive layer can be, for example, between about 10 μm and 200 μm, although the thickness can be determined based on any number of parameters and can be any suitable size.

[0053] Embodiments of the present disclosure provide a CMC sandwich structure suitable for applications at high temperatures, high specific stiffness, including (by way of non-limiting example) aerodynamic control surfaces (such as fins, flaps, ailerons, and elevons) and reentry vehicle structures where the structural surfaces are exposed to extremely high temperatures during reentry or flight. Various embodiments of the present disclosure may be incorporated into vehicles configured to be subsonic, transonic, supersonic, or hypersonic, such as (by way of non-limiting example) missiles and various types of aerospace vehicles (such as aircraft-like spacecraft). In an exemplary embodiment, the CMC sandwich structure includes a monolithic ceramic core structure configured to have multiple functions. By way of non-limiting example, this monolithic core structure has a higher thermal conductivity compared to conventional CMC materials. Thus, embodiments of the present disclosure are capable of modifying the structure to optimize the thermal response at the local and bulk levels. Additionally, compared to conventional CMC materials, the monolithic material has greater stiffness, and the additive manufacturing of the monolithic core structure can optimize the local and overall stiffness of the structure. High-temperature CMC layers are laminated to the monolithic core structure to form the CMC sandwich structure. The monolithic core structure may be printed, machined, or fabricated by other known methods, using monolithic ceramics as single or multiple core segments to achieve the overall aerodynamic structure. The core or core segments may include regions or features for integration and engagement with CMC layers and components within the structure to enhance functional performance and reliability. For example, in an exemplary embodiment, a single-piece monolithic core may include: pockets and interlocking features for internal attachment or for placement of CMC layers or CMC inserts; a leading edge having an aerodynamic shape with an internal edge for the arrangement of CMC panel layers; a backbone framework of different-shaped walls for managing local structural stiffness; and mating features for adaptation to engagement with the monolithic ceramic core structure.

[0054] As used herein, the term "subsonic" refers to a speed less than the speed of sound, which is less than about 1 Mach. As used herein, the term "transonic" refers to a speed of from about 0.8 Mach to about 1.2 Mach. As used herein, the term "supersonic" refers to a speed greater than the speed of sound, and more specifically, a speed of from about 1 Mach to about 5 Mach. As used herein, the term "hypersonic" refers to a speed of about 5 Mach and above.

[0055] Now referring to the drawings, where like numbers represent like elements throughout the drawings, Figure 1 a top view of an exemplary aerospace vehicle is provided, the aerospace vehicle in the form of vehicle 10, which may incorporate various embodiments of the present disclosure, and Figure 2 is provided as Figure 1 shown in a port 24 view of vehicle 10. Although Figure 1 and Figure 2Depicts an aerospace vehicle that is typically configured to be subsonic, but it should be understood that various embodiments of the present disclosure can be incorporated into aerospace vehicles configured to be subsonic, transonic, supersonic, or hypersonic or in reentry conditions in the Earth and other atmospheric conditions, e.g., by way of non-limiting example, missiles and various types of aerospace vehicles such as airplane-like spacecraft.

[0056] As Figure 1 and Figure 2 Collectively shown, the vehicle 10 defines a longitudinal direction L, a vertical direction V, a transverse direction T, a front end 14, and a rear end 16 extending therethrough. Additionally, the vehicle 10 includes a fuselage 20 that extends longitudinally from the front end 14 of the vehicle 10 to the rear end 16 of the vehicle 10, and a pair of wings 22, or rather, a first wing 22A and a second wing 22B. The first wing 22A extends outwardly from the port side 24 of the fuselage 20 generally along the transverse direction T relative to the longitudinal direction L from the fuselage 20. Additionally, the second wing 22B similarly extends outwardly from the starboard side 26 of the fuselage 20 generally along the transverse direction T relative to the longitudinal direction L from the fuselage 20. Each of the wings 22A, 22B generally includes a wing body 46. The fuselage 20 also includes an outer surface 40.

[0057] The vehicle 10 also includes a plurality of control surfaces for particular vehicle 10 maneuvers or operations. These control surfaces can be referred to as fins, stabilizers, flaps, ailerons, elevons, etc. For example, each of the wings 22A, 22B in the illustrated exemplary embodiment includes one or more leading-edge flaps 28 and one or more trailing-edge flaps 30. The vehicle 10 also includes a vertical stabilizer 32 having a rudder flap 34 for yaw control; and a pair of horizontal stabilizers 36, each horizontal stabilizer having an elevator flap 38 for pitch control. However, it should be understood that in other exemplary embodiments of the present disclosure, the vehicle 10 can additionally or alternatively include any other suitable configuration of control surfaces that may or may not extend directly along the vertical direction V or the horizontal / transverse direction T. Additionally, alternative control surfaces can be of any suitable shape, size, configuration, or orientation while still being within the scope of the subject matter.

[0058] Figure 1 and Figure 2The exemplary aircraft 10 therein further includes a propulsion system. The illustrated exemplary propulsion system includes a plurality of aircraft engines, with at least one mounted to each of a pair of wings 22A, 22B. Specifically, the plurality of aircraft engines includes a first aircraft engine 42 mounted to the first wing 22A and a second aircraft engine 44 mounted to the second wing 22B. In at least some exemplary embodiments, the aircraft engines 42, 44 may be configured as turbofan jet engines and suspended below the wings 22A, 22B in an under-wing configuration. However, alternatively, in other exemplary embodiments, any other suitable aircraft engine may be provided. For example, in other exemplary embodiments, the first and / or second aircraft engines 42, 44 may alternatively be configured as turbojet engines, turboshaft engines, turboprop engines, etc. It should also be understood that embodiments of the present disclosure may be incorporated into other types of propulsion systems, for example, by way of non-limiting example, ramjet engines or supersonic combustion ramjet (SCRAM) engines.

[0059] Figure 1 and Figure 2 One or both of the first aircraft engine 42 and the second aircraft engine 44 of the exemplary aircraft 10 described in Figure 3 may be configured in substantially the same manner as the exemplary gas turbine engine 100 of Figure 3 For the embodiments of Figure 3 shown, the gas turbine engine 100 is a high-bypass turbofan jet engine, sometimes also referred to as a "turbofan engine". As

[0060] shown, the gas turbine engine 100 defines an axial direction A (extending parallel to a longitudinal centerline 112 provided for reference), a radial direction R, and a circumferential direction C extending about the longitudinal centerline 112. Generally, the gas turbine engine 100 includes a fan section 114 and a turbine 116 disposed downstream of the fan section 114.

[0060] The illustrated exemplary turbine 116 generally includes a substantially tubular outer casing or core shroud 118 that defines an annular engine inlet 120. The core shroud 118 surrounds a compressor section in a series flow relationship, which includes a booster or low-pressure (LP) compressor 122 and a high-pressure (HP) compressor 124; a combustion section 126; a turbine section, which includes a high-pressure (HP) turbine 128 and a low-pressure (LP) turbine 130; and an exhaust nozzle section 132. A high-pressure (HP) shaft 134 (which may additionally or alternatively be a spool) drivingly connects the HP turbine 128 to the HP compressor 124. A low-pressure (LP) shaft 136 (which may additionally or alternatively be a spool) drivingly connects the LP turbine 130 to the LP compressor 122. The compressor section, the combustion section 126, the turbine section, and the exhaust nozzle section 132 together define a working gas flow path 137.

[0061] For the illustrated embodiment, the fan section 114 includes a fan 138 having a plurality of fan blades 140 that are coupled to a disk 142 in a spaced-apart manner. As shown, the fan blades 140 extend generally radially outward from the disk 142 along a radial direction R. The gas turbine engine 100 also includes a power gearbox 146, and the fan blades 140 and the disk 142 are rotatable together about a longitudinal centerline 112 via an LP shaft 136 that spans the power gearbox 146. The power gearbox 146 includes a plurality of gears for adjusting the rotational speed of the fan 138 relative to the rotational speed of the LP shaft 136 such that the fan 138 can rotate at a more efficient fan speed.

[0062] Still referring to Figure 3 the exemplary embodiment of, the disk 142 is covered by a rotatable front hub 148 (sometimes also referred to as a " spinner ") of the fan section 114. The front hub 148 has an aerodynamic profile to facilitate airflow through the plurality of fan blades 140.

[0063] In addition, the exemplary fan section 114 includes an annular fan casing or nacelle 150 that circumferentially surrounds at least a portion of the fan 138 and / or the turbine 116. It should be understood that in the illustrated embodiment, the nacelle 150 is supported relative to the turbine 116 by a plurality of circumferentially spaced outlet guide vanes 152. Further, a downstream section 154 of the nacelle 150 extends over an outer portion of the turbine 116, thereby defining a bypass airflow passage 156 therebetween.

[0064] During operation of the gas turbine engine 100, a quantity of air 158 enters the gas turbine engine 100 through an associated inlet 160 of the nacelle 150 and the fan section 114. As the quantity of air 158 passes through the fan blades 140, a first portion 162 of the air is directed or guided into the bypass airflow passage 156, while a second portion 164 of the air is directed or guided into the working gas flow path 137, or more specifically, into the LP compressor 122. The ratio between the mass flow rates of the first portion 162 of the air and the second portion 164 of the air is commonly referred to as the bypass ratio. Then, as the second portion 164 of the air is directed through the HP compressor 124 and into the combustion section 126, its pressure increases, and in the combustion section 126, the second portion 164 of the air is mixed with fuel and burned to provide combustion gases 166.

[0065] The combustion gases 166 are directed through the HP turbine 128, where a portion of the thermal energy and / or kinetic energy from the combustion gases 166 is extracted via successive stages of HP turbine stator vanes 168 coupled to the outer casing 118 and HP turbine rotor blades 170 coupled to the HP shaft 134, causing the HP shaft 134 to rotate and thereby supporting the operation of the HP compressor 124. The combustion gases 166 are then directed through the LP turbine 130, where a second portion of thermal energy and kinetic energy is extracted from the combustion gases 166 via successive stages of LP turbine stator vanes 172 coupled to the outer casing 118 and LP turbine rotor blades 174 coupled to the LP shaft 136, causing the LP shaft 136 to rotate and thereby supporting the operation of the LP compressor 122 and / or the rotation of the fan 138.

[0066] Subsequently, the combustion gases 166 are directed through the jet exhaust nozzle section 132 and exit the core cowl 118 through the core nozzle 167 of the turbine 116 to provide propulsive thrust. At the same time, as a first portion 162 of the air is directed through the bypass air flow path 156, the pressure of the first portion 162 of the air is significantly increased and then discharged from the fan exhaust nozzle section 176 of the gas turbine engine 100, also providing propulsive thrust. The HP turbine 128, the LP turbine 130, and the jet exhaust nozzle section 132 at least partially define a hot gas path 178 for directing the combustion gases 166 through the turbine 116.

[0067] However, it should be understood that Figure 3 the exemplary gas turbine engine 100 shown is by way of example only, and in other exemplary embodiments, the gas turbine engine 100 may have any other suitable configuration. For example, although the gas turbine engine 100 shown is configured as a geared gas turbine engine (i.e., includes a power gearbox 146), in other embodiments, the gas turbine engine 100 may additionally or alternatively be configured as a direct drive gas turbine engine (such that the LP shaft 136 rotates at the same speed as the fan 138). It should also be understood that in other exemplary embodiments, aspects of the present disclosure may be incorporated into any other suitable gas turbine engine. For example, in other exemplary embodiments, aspects of the present disclosure may (as appropriate) be incorporated into, for example, a turboshaft gas turbine engine or a turbojet gas turbine engine. It should be understood that the engine 100 may also include other types of propulsion systems, such as a hybrid electric turbofan engine or an electric propulsion system, and may include an electric drive fan. It should be understood that the various embodiments of the present disclosure may be incorporated into various components of the gas turbine engine 100, for example, by way of non-limiting example, the core nozzle 167, the low pressure turbine 130, and the jet exhaust nozzle section 132, including exhaust flap seals and similar structures.

[0068] See Figure 4, shows a ceramic composite component 200 in an assembled configuration, and the ceramic composite component 200 is in the form of a fin 202. For example, the fin 202 can be used for Figure 1 and Figure 2 on the aircraft 10 shown in or otherwise form a part of the aircraft 10. For example, the fin 202 can have a leading edge 201, a trailing edge 203, and one or more side edges 205, 207, and 209. However, it should be understood that other types of control surfaces or control surface structures, or other types of structures and components can generally be formed without departing from the present disclosure. In the illustrated embodiment, the ceramic composite component 200 includes a ceramic core structure 204, a CMC structure 206, and one or more CMC panels 208, and the one or more CMC panels 208 are disposed on and adhered to the ceramic core structure 204 and the CMC structure 206. In the illustrated embodiment, the CMC structure 206 extends outwardly beyond the side edges 207 and 209 to facilitate coupling the fin 202 to another structure. Similarly, the CMC structure 206 can be formed as a "receiving" or "receptor" internal structure to couple the ceramic composite component 200 to another structure via a receiving shaft or other form of coupling.

[0069] The ceramic core structure 204 can include a material different from the CMC panel 208 or the CMC structure 206. As a non-limiting example, the ceramic core structure 204 can be, for example, a material having a density less than that of the CMC panel 208 or the CMC structure 206. In some embodiments, the ceramic core structure 204 can include a foam core or other porous ceramic material core. However, even if the material of the ceramic core structure 204 is different, it can be compatible with the CMC panel 208 or the CMC structure 206 to create sufficient adhesion between the components, including under extreme operating conditions such as high temperatures. In an exemplary embodiment, the ceramic core structure 204 can include silicon carbide (SiC) or silicon (Si) (e.g., un-reinforced).

[0070] In Figure 5 the illustrated embodiment, the CMC panel 208 is adhered to the outer surface of the ceramic composite component 200. For example, referring to Figure 5, the CMC panel 208A is bonded to the side 210 of the ceramic core structure 204. For ease of illustration and clarity, the side 210 may also be referred to as the side 210. The CMC panel 208B is also bonded to the side 212 of the ceramic core structure 204 that is opposite to the side 210. For ease of illustration and clarity, the side 212 may also be referred to as the bottom side 212. The CMC panel 208A is also bonded to the side 214 of the CMC structure 206. For ease of illustration and clarity, the side 214 of the CMC structure 206 may also be referred to as the top side 214 of the CMC structure 206. The CMC panel 208B is also bonded to the side 216 of the CMC structure 206 that is opposite to the side 214. For ease of illustration and clarity, the side 216 of the CMC structure 206 may also be referred to as the bottom side 216 of the CMC structure 206. It should be understood that the CMC panel 208 may also extend and bond to other surfaces or sides of the ceramic core structure 204 and the CMC structure 206 that are not shown in Figure 5 . It should also be understood that the CMC panel 208 may include one or more CMC panels 208 such that one or more CMC panels 208 include different CMC panel 208 portions or segments that are continuous or discontinuous relative to each other and are disposed on different surfaces of the ceramic core structure 204 and the CMC structure 206 (e.g., on the same side or different sides of the ceramic core structure 204 and the CMC structure 206).

[0071] In the illustrated embodiment, the CMC structure 206 is provided, disposed, or otherwise embedded in the ceramic core structure 204. For example, in Figure 5 , the CMC structure 206 is formed in the shape of a shaft such that the side 214 of the CMC structure 206 (where it intersects with the adjacent side 210 of the ceramic core structure 204) is aligned or flush with the adjacent side 210. Similarly, the CMC structure 206 is formed such that its side 216 (where the side 216 intersects with the adjacent side 212 of the ceramic core structure 204) is aligned or flush with the adjacent side 212. It should be understood that the sides 210 and 214 and the sides 212 and 216 may include contours or geometries to meet the specific design requirements of the ceramic composite component 200.

[0072] In the illustrated embodiment, the ceramic core structure 204 includes interlock features 218 that engage corresponding and geometrically complementary interlock features 220 formed on the CMC structure 206. For example, in the illustrated embodiment, the interlock features 218 include a pair of grooves 222, each groove formed in respective sidewalls 224 and 226 of the ceramic core structure 204. The interlock features 220 include a pair of protrusions 228, each protrusion formed in or extending outwardly from respective sidewalls 230 and 232 of the CMC structure 206. In operation, the interlock features 218 and 220 engage each other to prevent the CMC structure 206 from undesirably separating from the ceramic core structure 204. The interlock features 218 and 220 can include other types of geometric features, such as but not limited to dovetails, mortises and tenons, keyholes, or other types of fixed geometries.

[0073] The CMC structure 206 can also be bonded to the ceramic core structure 204. For example, in an exemplary embodiment, as will be described in more detail below, a flexible matrix material or other material or method can be used at the component interface to bond the CMC structure 206 to the ceramic core structure 204.

[0074] In an exemplary embodiment, the ceramic core structure 204 includes a monolithic ceramic core structure 204 such that the ceramic core structure 204 can be formed without reinforcing fibers. As a further non-limiting example, the ceramic core structure 204 can be an additive manufacturing structure. In an exemplary embodiment, the ceramic core structure 204 can be a honeycomb structure. In an exemplary embodiment, the ceramic core structure 204 is made of Si or SiC. It should be understood that the ceramic core structure 204 can include other types of honeycomb structures. Referring to Figure 6 , it can be seen that the outer perimeter or boundary of the ceramic core structure 204 is defined by sidewalls 240, 242, 244, 246, and 248. The ceramic core structure 204 includes a recessed portion 254 sized and configured to receive the CMC structure 206( Figure 5)。In the illustrated embodiment, the recessed portion 254 is defined by sidewalls 224 and 226 and sidewall 256, each sidewall extending from side 210 to side 212. The recessed portion 254 extends inwardly from sidewalls 240 and 242 (e.g., sidewall 226 extends inwardly from sidewall 242, and sidewall 224 extends inwardly from sidewall 240) into the interior region or portion of the ceramic core structure 204. In an exemplary embodiment, the ceramic core structure 204 may be formed as a monolithic integral core structure. The ceramic core structure 204 includes a plurality of hollow cells 260 defined by a plurality of walls 262 that extend from side 210 of the ceramic core structure 204 to side 212 of the ceramic core structure 204 that is opposite side 210. Each of the plurality of hollow cells 260 that form the ceramic core structure 204 may extend in a direction parallel to each other. Additionally, side 210 and side 212 may be planar or non-planar, having planar and non-planar segments, or a combination of planar and non-planar geometries. In Figure 7 the illustrated embodiment, sides 210 and 212 are tapered in one or more directions to create an aerodynamic surface at sides 210 and 212.

[0075] As Figure 8 shown, the plurality of walls 262 of the plurality of hollow cells 260 define the shape of each of the plurality of hollow cells 260, and more specifically, the cross-sectional geometry 264. That is, the plurality of walls 262 create a partially enclosed structure (i.e., surrounded by the plurality of walls 262 on one side, but may be open at the ends of side 210 or side 212) to define a hollow interior 266, thereby forming the cross-sectional geometry 264 of each of the plurality of cells 260. As used herein, the cross-sectional geometry 264 refers to the open or enclosed space between the plurality of walls 262 at any point along the length of any individual cell 260. The ceramic core structure 204 may also include a cross-sectional geometry 264 that is non-uniform from side 210 to side 212. The cross-sectional geometry 264 may be hexagonal, circular, square, triangular, and the like.

[0076] While the ceramic core structure 204 is depicted as having a plurality of hollow cells 260 of uniform size that are parallel to each other, it should be understood that various alternative or additional configurations are also within the scope of the present disclosure. For example, the plurality of hollow cells 260 can include different geometries, different orientations, and cells having different sizes at different portions of the ceramic core structure 204 to meet different functional requirements. Additionally, the cross-sectional geometry 264 can have an open cross-sectional area that is smaller, larger, or has a different shape at one or more locations along at least a portion of one of the plurality of hollow cells 260. For example, the cross-sectional geometry 264 from side 210 to side 212 can be uniform for one or more of the plurality of hollow cells 260. That is, the hollow cell 260 will have the same cross-sectional geometry 264 over its entire length.

[0077] Alternatively or additionally, one or more of the plurality of hollow cells 260 can include a non-uniform cross-sectional geometry 264 from side 210 to side 212. That is, the cross-sectional geometry 264 can have a smaller, larger open cross-sectional area, or a geometry having a different shape at one or more locations along at least one of the plurality of hollow cells 260 to provide an overall cross-sectional geometry 264 that is non-uniform between its side 210 and side 212. Having a non-uniform cross-sectional geometry 264 can be beneficial for enhancing adhesion to the CMC panel 208, for example, by providing additional material or surface area at side 210 or side 212 of the ceramic core structure 204 while still reducing the overall amount of material used in the ceramic core structure 204 via the overall configuration of the plurality of hollow cells 260.

[0078] In an exemplary embodiment, at least one of the plurality of hollow cells 260 of the ceramic core structure 204 has a mid-span cross-sectional geometry 264 that has an approximately 3 / 8” open cell 260 size between side 210 and side 212 and has partially enclosed ends 268 and 270 of the cell 260 at the respective sides 210 and 212. As used herein, mid-span refers to any location between side 210 and side 212, whether located midway between the two or biased towards side 210 or side 212. In an exemplary embodiment, the partially enclosed ends 268 and 270 are formed during additive manufacturing of the ceramic core structure 204. However, in other exemplary embodiments, the ceramic core structure 204 can be additively manufactured without the partially enclosed ends 268 and 270 (e.g., having solid sides 210 and 212) such that the sides 210 and 212 are subsequently perforated to form the partially enclosed ends 268 and 270.

[0079] Figure 9illustrates that the ceramic core structure 204 can be additively manufactured, where one or more channels or holes 280 extend through one or more walls 262 to fluidly link adjacent cells 260 disposed therebetween. In an exemplary embodiment, the holes 280 can be located in the wall 262 at any mid-span position between side 210 ( Figure 8 ) and side 212 ( Figure 8 ). In an exemplary embodiment, the holes 280 form a fluid flow path within the ceramic core structure 204 (e.g., for heating, cooling, etc.). In the illustrated embodiment, the holes 280 are depicted as extending in a single direction or being unidirectional with respect to the ceramic core structure 204. However, it should be understood that the holes 280 can be formed in different directions and have different geometries. It should also be understood that one or more holes 280 can be formed in any particular single wall 262.

[0080] In an exemplary embodiment, the additively manufactured ceramic core structure 204 undergoes a densification process such that the ceramic core structure 204 is pyrolyzed and melt infiltrated prior to further assembly operations. In an exemplary embodiment, the ceramic core structure 204 comprises a SiC monolithic ceramic core structure 204 such that after 3D printing, the ceramic core structure 204 is a combination of SiC and C. During the melt infiltration of the ceramic core structure 204, Si is applied to the ceramic core structure 204 and, during melt infiltration, Si infiltrates the ceramic core structure 204. During melt infiltration, Si reacts with C in the ceramic core structure 204 to form new, additional SiC and consolidate the ceramic core structure 204. In this way, the ceramic core structure 204 can be considered a monolithic ceramic core structure.

[0081] Figure 10 is a schematic diagram of an exemplary embodiment of a CMC structure 300 according to an embodiment of the present disclosure. The CMC structure 300 can be used as a CMC structure 206 ( Figure 4 and Figure 5 ), which forms part of a ceramic composite component 200 ( Figure 4 and Figure 5 ). In the illustrated embodiment, the CMC structure 300 includes a number of CMC layers 302. Additionally, in an exemplary embodiment, the reinforcing fibers of the CMC layers 302 can be oriented in the longitudinal direction 303 of the CMC structure 300. However, it should be understood that the CMC layers 302 can be laid such that the orientation of the reinforcing fibers of the CMC layers 302 can be otherwise configured such that the layer architecture of the CMC layers 302 is optimized based on the specific loads of a particular application.

[0082] For purposes of illustration and clarity, side 304 of CMC structure 300 may also be referred to as the top side 304 of CMC structure 300. For purposes of illustration and clarity, the side 306 of CMC structure 300 that is opposite side 304 may also be referred to as the bottom side 306 of CMC structure 300. Side 304 and side 306 of CMC structure 300 may correspond to side 214 and side 216 of CMC structure 206, respectively ( Figure 4 and Figure 5 ). In the illustrated embodiment, CMC structure 300 also includes side walls 308 and 310. Side walls 308 and 310 may correspond to side walls 230 and 232 of CMC structure 206, respectively ( Figure 4 and Figure 5 ). In Figure 10 , for purposes of illustration and description, CMC structure 300 is depicted as not having interlocking features (e.g., interlocking features 220 of CMC structure 206 ( Figure 4 and Figure 5 )); however, it should be understood that CMC structure 300 may be configured with such interlocking features, e.g., similar to interlocking features 220 of CMC structure 206 ( Figure 5 ), to engage correspondingly with interlocking features 218 of ceramic core structure 204 ( Figure 5 ). The integration between the CMC structure 300 axis and the complex aerodynamic control surface may include interlocking features such as dovetails, mortises and tenons, keyholes, or similar retaining features to prevent the CMC structure 300 from separating from such other surfaces or components.

[0083] In Figure 10 , CMC structure 300 includes a non-tapered portion 311 and a tapered portion 312. The non-tapered portion 311 is formed or configured to have a substantially constant thickness (e.g., in its length, width, and depth), while the tapered portion 312 is formed or configured such that at least a portion of side 304, side 306, and side walls 308 and 310 is tapered (e.g., tapered inwardly in the illustrated embodiment). However, it should be understood that the geometric configuration of CMC structure 300 may vary. In Figure 10 , the size and geometric configuration of CMC structure 300 are designed to be geometrically complementary to the recessed portion 254 of ceramic core structure 204 ( Figure 6 and Figure 7 ) such that when CMC structure 300 is disposed within the recessed portion 254 of ceramic core structure 204 ( Figure 5-7 ), side 304 and side 306 of CMC structure 300 are aligned or flush with the corresponding adjacent sides 210 and 212 of ceramic core structure 204 ( Figure 5-7 ). For example, in the assembled position, at least a portion of the tapered portion 312 is disposed within the recessed portion 254 of ceramic core structure 204 (Figure 5-7 ) such that the sidewall 314 of the CMC structure 300 is disposed adjacent to and abuts against the sidewall 256 of the ceramic core structure 204 Figure 5-7 ). At the above reference position with respect to the ceramic core structure 204 Figure 5-7 ), at least a portion 316 of the non-tapered portion 311 extends beyond the sidewalls 240 and 242 of the ceramic core structure 204 Figure 4-7 ) and is located outside the groove portion 254. In the illustrated embodiment, the CMC structure 300 has a rectangular cross-section; however, it should be understood that for cost, performance, or other driving factors, the CMC structure 300 can be formed or configured to have other geometries and cross-sectional areas. Additionally, it should be understood that the desired geometric configuration of the CMC structure 300 can be formed based on the shape, configuration, or layup of the CMC layer 302, or the CMC structure 300 can be machined or cut into the desired shape after burnout and melt infiltration of the CMC layer 302. The CMC structure 300 can have straight, tapered, or rounded edges, corners, or both. As a non-limiting example, the corners of the CMC structure 300 can be rounded to minimize contact stress.

[0084] In an exemplary embodiment, the CMC layer 302 undergoes densification. Thus, in this embodiment, a silicon-based matrix material is applied to the CMC layer 302 that forms the CMC structure 300 such that the CMC structure 300 burns out and undergoes a melt infiltration process. As described above, after the melt infiltration process, the CMC structure 300 can be machined or cut into the desired shape or geometric configuration.

[0085] Figure 11 is a schematic view of an exemplary embodiment of a CMC structure 390 according to another embodiment of the present disclosure. The CMC structure 390 can be used as the CMC structure 206 Figure 4 and Figure 5 ), which forms part of the ceramic composite component 200 Figure 4 and Figure 5 ). It should also be understood that in alternative embodiments of the ceramic composite component 200 Figure 4 and Figure 5 ), multiple CMC structures can be used in the ceramic composite component 200 Figure 4 and Figure 5 ). As a non-limiting example, the CMC structure 300 Figure 10 ) and the CMC structure 390 or aspects or portions thereof can be used simultaneously in the ceramic composite component 200 Figure 4 and Figure 5 ).

[0086] In the illustrated embodiment, the CMC structure 390 includes CMC panels 398, 400 and a ceramic core structure 403 disposed or sandwiched between CMC panels 398 and 400. Each of CMC panels 398 and 400 includes a number of CMC layers 402 (e.g., one or more CMC layers 402a and one or more CMC layers 402b, which form corresponding panels 398 and 400). For purposes of illustration and clarity, side 404 of CMC structure 390 may also be referred to as the top side 404 of CMC structure 390. For purposes of illustration and clarity, side 406 of CMC structure 390 opposite side 404 may also be referred to as the bottom side 406 of CMC structure 390. Side 404 and side 406 of CMC structure 390 may respectively correspond to side 214 and side 216 of CMC structure 206 ( Figure 4 and Figure 5 ). In the illustrated embodiment, CMC structure 390 also includes side walls 408 and 410. Side walls 408 and 410 may respectively correspond to side walls 230 and 232 of CMC structure 206 ( Figure 4 and Figure 5 ). In Figure 11 , for purposes of illustration and description, CMC structure 390 is shown without interlocking features (e.g., interlocking features 220 of CMC structure 206 ( Figure 4 and Figure 5 )); however, it should be understood that CMC structure 390 may be configured with such interlocking features, such as similar to interlocking features 220 of CMC structure 206 ( Figure 5 ), to engage correspondingly with interlocking features 218 of ceramic core structure 204 ( Figure 5 ).

[0087] In Figure 11In the [description], the CMC structure 390 includes a non-tapered portion 411 and a tapered portion 412. The non-tapered portion 411 is formed or configured to have a substantially constant thickness (e.g., in its length, width, and depth), and the tapered portion 412 is formed or configured such that at least a portion of sides 404, 406, and side walls 408 and 410 is tapered (e.g., tapered inwardly in the illustrated embodiment). However, it should be understood that the geometric configuration of the CMC structure 390 can vary. In an exemplary embodiment, panels 398 and 400 are formed to have a constant (or substantially constant) thickness, which is measured in the direction extending from side 404 to side 406. In the illustrated embodiment, the ceramic core structure 403 is configured or formed such that its thickness measured in the direction extending from side 404 to side 406 varies in thickness to produce the tapered portion 412. In an exemplary embodiment, the thickness of the ceramic core structure 403 is configured to have a thickness measured in the direction extending from side 404 to side 406 as a percentage of the overall thickness of the CMC structure 390 measured in the corresponding direction. In an exemplary embodiment, the thickness of the ceramic core structure 403 measured in the direction extending from side 404 to side 406 is half (or approximately half) of the overall thickness of the CMC structure 390 measured in the corresponding direction.

[0088] In Figure 11 the [description], the size and geometric configuration of the CMC structure 390 are designed to be geometrically complementary to the groove portion 254 of the ceramic core structure 204 ( Figure 6 and Figure 7 ), such that when the CMC structure 390 is disposed within the groove portion 254 of the ceramic core structure 204 ( Figure 5-7 ), sides 304 and 306 of the CMC structure 390 are aligned or flush with the corresponding adjacent sides 210 and 212 of the ceramic core structure 204 ( Figure 5-7 ). For example, in the assembled position of the ceramic composite component 200 ( Figure 4 ), the tapered portion 412 is disposed within the groove portion 254 of the ceramic core structure 204 ( Figure 5-7 ), such that the side wall 414 of the CMC structure 390 is disposed adjacent to and abuts against the side wall 256 of the ceramic core structure 204 ( Figure 5-7 ). In the above reference position relative to the ceramic core structure 204 ( Figure 5-7 ), at least a portion 416 of the non-tapered portion 411 extends beyond the side walls 240 and 242 of the ceramic core structure 204 ( Figure 4-7) and is disposed outside the recessed portion 254. In the illustrated embodiment, at least a portion of the CMC structure 390 is rectangular; however, it should be understood that the CMC structure 390 can be formed or configured to have other geometric shapes and cross-sectional areas, and its cross-sectional geometry can vary along its width, length, or depth. Additionally, it should be understood that the desired geometric configuration of the CMC structure 390 can be formed based on the shape, configuration, or layup of the CMC layer 402 and the ceramic core structure 403, or the CMC structure 390 can be machined or cut into the desired shape after burnout and melt infiltration of the CMC structure 390.

[0089] In an exemplary embodiment, the ceramic core structure 403 can be formed similar to the ceramic core structure 204 ( Figure 6 ) formed. In an exemplary embodiment, the ceramic core structure 403 can include a material different from the CMC layer 402. As a non-limiting example, the ceramic core structure 403 can be such a material with a density less than that of the CMC layer 402. In an exemplary embodiment, the ceramic core structure 403 can include a foam core or other porous ceramic material or a solid ceramic material. However, even if the material of the ceramic core structure 403 is different, it can be compatible with the CMC layer 402 to create sufficient adhesion between the components, including under extreme operating conditions such as high temperatures. In an exemplary embodiment, the ceramic core structure 403 can include silicon carbide (SiC) or silicon (Si).

[0090] In an exemplary embodiment, the ceramic core structure 403 includes an additively manufactured structured honeycomb core using monolithic SiC. The additive manufacturing processes cited herein can be used to form a ceramic core structure 403 having one or more ceramic base layers using any suitable ceramic particulate compound. For example, the additively manufactured ceramic core structure can be produced via binder jet printing or other additive manufacturing techniques. However, the additively manufactured ceramic core structure 403 may require debulking (e.g., removing loose powder from its hollow interior). In an exemplary embodiment, the ceramic core structure 403 produced by the additive manufacturing process undergoes a densification process such that the ceramic core structure 403 is pyrolyzed and melt infiltrated before the CMC layers 402a and 402b are applied to the ceramic core structure 403. In an exemplary embodiment, the ceramic core structure 403 includes a monolithic SiC ceramic core structure 403 such that after 3D printing, the ceramic core structure 403 is a combination of SiC and C. During melt infiltration of the ceramic core structure 403, Si is applied to the ceramic core structure 403, and during melt infiltration, Si penetrates the ceramic core structure 403. During melt infiltration, Si reacts with C in the ceramic core structure 403 to form new, additional SiC and consolidate the ceramic core structure 403 (e.g., form a monolithic ceramic core structure).

[0091] In an exemplary embodiment, the ceramic core structure 403 includes a plurality of hollow cells 424 defined by a plurality of walls 426 that extend from a side 420 of the ceramic core structure 403 to an opposite side 422 of the ceramic core structure 403 relative to the side 420. In an exemplary embodiment, the ceramic core structure 403 can be used as a mandrel such that CMC layers 402a and 402b are applied to the side 420 and side 422 of the ceramic core structure 403 to form corresponding panels 398 and 400. In an exemplary embodiment in accordance with the present disclosure, the ceramic core structure 403 serves as a mandrel such that a certain number of CMC layers 402a and 402b are laid on the respective sides 420 and 422 of the ceramic core structure 403 and processed as described herein (e.g., subjected to heat treatment and / or chemical treatment) to form the panel 398 and panel 400, respectively. In an exemplary additional or alternative embodiment, the ceramic core structure 403 can include a solid SiC structure (e.g., a solid core formed by additive manufacturing of monolithic SiC). The ceramic core structure 403 configured as a solid SiC structure can be subjected to heat treatment and chemical treatment as described above (e.g., pyrolysis and melt infiltration).

[0092] In an exemplary embodiment, the panels 398 and 400 extend through the respective sides 420 and 422 of the ceramic core structure 403 such that the panels 398 and 400 terminate at a location that coincides with the perimeter or boundary of the ceramic core structure 403. Additionally, in an exemplary embodiment, the reinforcing fibers of the CMC layer 402a and the CMC layer 402b can be oriented in the longitudinal direction 428 of the CMC structure 390. However, it should be understood that the CMC layers 402a and 402b can be applied to the ceramic core structure 403 such that the orientation of the reinforcing fibers of the CMC layers 402a and 402b can be configured otherwise.

[0093] In an exemplary embodiment, after melt infiltration of the ceramic core structure 403, the CMC layers 402a and 402b are applied to the ceramic core structure 403. The CMC layers 402a and 402b can be subjected to heat treatment, such as curing or burnout to produce a high-carbon residue, and then chemically treated together with the ceramic core structure 403 (e.g., melt infiltration with silicon). Thus, in this embodiment, a silicon-based matrix material is applied to the CMC layers 402a and 402b and the ceramic core structure 403 that form the respective panels 398 and 400 such that the ceramic core structure 403 and the CMC 402a and 402b that form the respective panels 398 and 400 are burned out and undergo a melt infiltration process together. Thus, the panels 398 and 400 form a seamless, integral monolithic structure with the ceramic core structure 403. After densification, the CMC structure 390 can be machined or cut into a desired geometric configuration.

[0094] Figure 12 is part of an exemplary ceramic composite component according to an embodiment of the present disclosure Figure 5 An enlarged view of part of an exemplary ceramic composite component. The ceramic composite component 200 utilizing a flexible matrix material 490 and its assembly method are shown. For example, the flexible matrix material 490 can be used to bond Figure 1-11 the components shown therein. Generally, the flexible matrix material 490 is a complementary material placed between the ceramic core structure 204 and the CMC structure 206, between the CMC panel 208 and the ceramic core structure 204 and the CMC structure 206, or any combination thereof, to bond the individual components together and accommodate dimensional mismatches. That is, the flexible matrix material 490 is capable of conforming (i.e., adopting the geometry and shape of the adjacent components) to the interface or interface surface (i.e., the surfaces to be bonded to each other) between the ceramic core structure 204 and the CMC structure 206, or between the CMC panel 208 and the ceramic core structure 204 and the CMC structure 206, or any combination thereof. Thus, for example, the flexible matrix material 490 helps to bond the CMC structure 206 to at least a portion of the wall 262 ( Figure 6 , 8 and 9) of the ceramic core structure 204. After application, the flexible matrix material 490 can be densified, for example by infiltration, to conform to and bond the adjacent components in the ceramic composite component 200. It should also be understood that the flexible matrix material 490 can also be placed between the ceramic core structure 403 ( Figure 11 ) and the panels 398 / panel 400 ( Figure 11 ) of the CMC structure 390 ( Figure 11 ).

[0095] The flexible matrix material 490 can be a ceramic filler material that includes a liquid carrier (such as a solvent), a powder component (including reactive and non-reactive ceramic precursor materials), and a polymeric binder (such as a resin) disposed in the liquid carrier. The liquid carrier of the flexible matrix material 490 can be selected such that it partially or completely dissolves one or more organic components in the formulation, such as the binder. In some embodiments, the liquid carrier can include water, one or more alcohols, or other organic liquids (such as acetone or toluene), or a combination thereof. The amount of the liquid carrier can also be adjusted to change the physical consistency of the flexible matrix material 490. For example, by increasing the amount of the liquid carrier, the flexible matrix material 490 can be applied as a flexible matrix material paste, or by decreasing the amount of the liquid carrier, the flexible matrix material 490 can be applied as a tape. For example, in some embodiments, the liquid carrier can include 50% to 70% by volume of the flexible matrix material 490, or 55% to 65% by volume of the flexible matrix material 490. Such embodiments can produce a flexible matrix material 490 that is fluid but has a low viscosity. In some embodiments, the liquid carrier can include 5% to 15% by volume of the flexible matrix material 490, or 7% to 13% by volume of the flexible matrix material 490. Such embodiments can produce a flexible matrix material 490 in the form of a tape or film.

[0096] The powder of the flexible matrix material 490 can include at least one of silicon, silicon carbide, or carbon, or other ceramic precursor materials for the final ceramic material composition, such as SiC or other carbides, carbon oxides, and other related materials. In some embodiments, the powder includes 10% to 90% by weight of carbon. In some embodiments, the powder includes 20% to 80% by weight of carbon. In some embodiments, the powder includes 30% to 70% by weight of carbon. In some embodiments, the powder includes 40% to 60% by weight of carbon. In some embodiments, the powder can additionally or alternatively include other forms of materials, such as fibrous materials. For example, the flexible matrix material 490 can include a woven material that includes randomly oriented carbon fibers, such as to form a tape. In some embodiments, the flexible matrix material 490 can include chopped fibers.

[0097] In some embodiments, the powder of the flexible matrix material 490 includes carbon and silicon carbide. The carbon or other reactive material can react with silicon during melt infiltration to form silicon carbide. For example, in some embodiments, the powder includes 40% to 60% by weight of carbon and 40% to 60% by weight of silicon carbide. In some embodiments, the powder includes 45% to 55% by weight of carbon and 45% to 55% by weight of silicon carbide.

[0098] The polymer binder of the flexible matrix material 490 can be used to modify the flow characteristics of the flexible matrix material 490, for example, by thickening the flexible matrix material 490 to allow it to remain in place (e.g., as a paste) when applied to the ceramic core structure 204 and the CMC structure 206, as described herein.

[0099] Optionally, the flexible matrix material 490 further includes other components disposed in a liquid carrier, such as a shrinkage control agent, which provides a degree of rigidity to the formulation during processing. For example, the mass loss associated with the volatilization of the liquid carrier and the conversion of the binder to carbon creates a driving force for the remaining material to shrink in size, and excessive shrinkage can lead to undesirable cracking within the product material. Including a shrinkage control agent (e.g., short fibers) can provide mechanical support to mitigate the shrinkage tendency. Alternatively, or in addition, the flexible matrix material 490 can include a plasticizer, a dispersant, other supplementary materials, or combinations thereof.

[0100] The flexible matrix material 490 (e.g., liquid carrier, powder, or polymer binder) can be selected to have substantially similar thermodynamic, physical, or chemical properties to the remaining components of the ceramic composite component 200 (e.g., such that the thermodynamic, physical, or chemical properties of the flexible matrix material 490 are well - matched to the thermodynamic, physical, or chemical properties of the ceramic core structure 204, the CMC structure 206, and the CMC panel 208).

[0101] For example, the flexible matrix material 490, the CMC panel 208, the ceramic core structure 204, and the CMC structure 206 can have substantially similar coefficients of thermal expansion, elastic moduli, thermal conductivities, oxidation resistances, material compatibilities, or chemical compositions. As an example, the flexible matrix material 490 can have material compatibility, which helps prevent adverse or undesirable reactions between the flexible matrix material 490 and the CMC panel 208, the ceramic core structure 204, and the CMC structure 206. Due to the substantially similar or well - matched thermodynamic, physical, or chemical properties, the joints between the ceramic core structure 204 and the CMC structure 206 or between the CMC panel 208 and the ceramic core structure 204 / CMC structure 206 do not need to be as precisely defined as in other requirements, because the flexible matrix material 490 can accommodate dimensional mismatches by filling the gaps.

[0102] As Figure 12As shown, a flexible matrix material 490 is disposed between the ceramic core structure 204 and the CMC structure 206. The flexible matrix material 490 is also disposed at other interface surfaces of the CMC panel 208, the ceramic core structure 204, and the CMC structure 206. However, it should be understood that in an exemplary embodiment, the flexible matrix material 490 may be omitted from certain locations. In an exemplary embodiment, since the CMC panel 208 can sufficiently accommodate the dimensional mismatch between the ceramic core structure 204 and the CMC structure 206, the flexible matrix material 490 between the CMC panel 208 and the ceramic core structure 204 and the CMC structure 206 may be omitted. The flexible matrix material 490 may be applied in a variety of configurations, for example, by laying a flexible matrix material paste or tape containing the flexible matrix material, or spraying the flexible matrix material.

[0103] In an exemplary embodiment, the flexible matrix material 490 may be applied as a conformal matrix layer. The conformal matrix layer may include a relatively flat and rigid structure that may be located between or at the interfaces of the CMC panel 208, the ceramic core structure 204, and the CMC structure 206. Alternatively, or additionally, in an exemplary embodiment, the flexible matrix material 490 may be applied as a flexible matrix material paste. The paste may be placed between the CMC panel 208, the ceramic core structure 204, and the CMC structure 206, on or around the joints between the ceramic core structure 204 and the CMC structure 206, or at other interface surfaces of the components. Any suitable application technique may be used for the paste, such as, but not limited to, brushing, injection, molding, etc. In some embodiments in which the flexible matrix material 490 includes a flexible matrix material paste, the flexible matrix material 49o may form a rounded corner between the CMC panel 208, the ceramic core structure 204, and the CMC structure 206. Due to the circular shape and material adhesion, such a rounded corner may help reduce stress concentration at the joints.

[0104] In an exemplary embodiment, the CMC panel 208 includes a certain number of CMC layers 500. Similar to that described above in connection with CMC layer 302 ( Figure 10 ) or CMC layer 402 ( Figure 11 ).

[0105] In the exemplary embodiment, CMC layer 500 is applied over or substantially covers the entire ceramic core structure 204 and CMC structure 206, such that CMC facesheet 208 substantially surrounds ceramic core structure 204 and CMC structure 206. As used herein, the terms "substantially surround" and "substantially surround" mean that at least 90% of the surface area of ceramic core structure 204 and CMC structure 206 is covered by CMC facesheet 208, for example, 95% of its surface area is covered by CMC facesheet 208. The terms "substantially surround" and "substantially surround" may include completely surrounding and completely surrounding, respectively. The reinforcing fibers of CMC layer 500 may be oriented in any desired direction based on the strength requirements and the load conditions that ceramic composite component 200 is expected to experience.

[0106] The ceramic composite part 200 also undergoes a densification process to densify the pliable matrix material 490 and the CMC layer 500, thereby bonding the pliable matrix material 490 and the CMC layer 500 to respective interfaces with the ceramic core structure 204 and the CMC structure 206. That is, the pliable matrix material 490 will form a conformal interface layer of matrix material that is densified, conforms to, and bonds to the ceramic core structure 204, the CMC structure 206, and the CMC facesheet 208.

[0107] Densification may include performing a burnout (or firing) and densifying the remaining material. For example, the pliable matrix material 490 and the CMC layer 500 may be heated (fired) in a vacuum or inert atmosphere to decompose any binder and remove any solvent in the pliable matrix material 490 and the CMC layer 500, thereby converting the pliable matrix material 490 and the CMC layer 500 into the desired ceramic matrix material. Due to the decomposition of the binder during the burnout process, the pliable matrix material 490 and the CMC layer 500 may be porous.

[0108] In some embodiments, densification may include densifying the pliable matrix material 490 and the CMC layer 500 with a densifying material via one or more infiltration processes. Infiltration may include melt infiltration (MI), chemical vapor infiltration (CVI), or polymer infiltration and pyrolysis (PIP) to fill the pores and produce the densified ceramic composite part 200. The specific densifying materials, processing techniques, and parameters of the above processes will depend on the specific composition of the materials.

[0109] For example, a silicon carbide CMC component may be infiltrated with molten silicon, such as by a silicon MI process or a reactive MI process. In some embodiments, prior to lamination, one or more components (e.g., the ceramic core structure 204 ( Figure 5-9 ), CMC structure 206, 300 or 390 ( Figure 5 、 10Densification of the ceramic composite component 200 (e.g., 200 and 11) or the CMC panel 208) may occur. Molten silicon may fill the pores while contacting the existing carbon to form silicon carbide. Other densification techniques include, but are not limited to, the PIP process (e.g., where a silicon carbide reinforced component is infiltrated with a pre-ceramic polymer (such as polysilazane) and then heat treated to form a SiC matrix), the oxide / oxide process (e.g., for aluminum or aluminosilicate reinforced components), and the CVI process (e.g., for carbon fiber reinforced silicon carbide matrix (C / SiC) CMCs, for SiC / SiC CMCs, etc.). Thus, in some embodiments, the densifying material may include silicon or silicon carbide. In some embodiments, the densifying material may include germanium. In some embodiments, the densifying material may include silicon, germanium, boron, silicon germanium, or combinations thereof. Using melt infiltration can reduce free silicon in the matrix, provide stronger properties for the composite plate, or define different structures in the resulting matrix. Additionally, densifying the material (e.g., to produce a silicon-bonded SiC matrix) can reduce porosity within the subsequent matrix, thereby producing a denser, stronger, and more durable bond that can withstand extreme operating conditions, including high temperatures. Due to densification, the ceramic composite component 200 will include a matrix material 490 that is densified and bonded to the ceramic core structure 204( Figure 5-9 ), the CMC structures 206, 300, or 390( Figure 5 , 10 and 11) and the CMC panel 208.

[0110] Figure 13 is a schematic view of another exemplary ceramic composite component 600 in accordance with an embodiment of the present disclosure. In the illustrated embodiment, the ceramic composite component 600 includes a portion of an airfoil 602. However, it should be understood that the ceramic composite component 600 can be used in other applications.

[0111] In an exemplary embodiment, the ceramic composite component 600 includes a ceramic core structure 610, a ceramic core structure 612, and CMC panels 614 and 616. In an exemplary embodiment, the ceramic core structure 610 includes an additive manufactured ceramic core structure 610. In an exemplary embodiment, the ceramic core structure 610 is a structured honeycomb core having one or more cavities or cells 617 defined by one or more walls 618. In an exemplary embodiment, the ceramic core structure 610 is a monolithic ceramic core structure 610. In an exemplary embodiment, the ceramic core structure 610 is made using Si or SiC. In an exemplary embodiment, the ceramic core structure 610 may be formed similar to the ceramic core structure 204( Figure 4-9 ), e.g., further including or not including holes 280( Figure 9). In an exemplary embodiment, the ceramic core structure 612 includes an additively manufactured ceramic core structure 612. In an exemplary embodiment, the ceramic core structure 612 is a solid core structure. In an exemplary embodiment, the ceramic core structure 612 is a monolithic ceramic core structure 612. In an exemplary embodiment, the ceramic core structure 612 is made of Si or SiC. In an exemplary embodiment, the ceramic core structure 612 may be similar to the ceramic core structure 204( Figure 4-9 ) formed, except as a solid, non-honeycomb structure. In an exemplary embodiment, each of the CMC panels 614 and 616 includes a certain number of corresponding CMC layers 620 and 622. The CMC panels 614 and 616 may be similar to the CMC panels 208( Figure 4 , 5 and 12), the CMC structure 300( Figure 10 ) formed, or similar to the CMC panels 398 and 400 of the CMC structure 390( Figure 11 ) formed.

[0112] In the illustrated embodiment, the ceramic composite component 600 includes a first end 630 and a second end 632. As Figure 13 shown, the ceramic composite component 600 includes a tapered configuration such that the ceramic composite component 600 tapers inwardly from the first end 630 towards the second end 632. However, it should be understood that the ceramic composite component 600 may include other geometric configurations. In the illustrated embodiment, the ceramic core structure 610 includes a surface 640 and a surface 642, and the ceramic core structure 612 includes a surface 650 and a surface 652. The surface 642 is opposite to the surface 640, and the surface 652 is opposite to the surface 650. In the illustrated embodiment, the ceramic core structure 610 includes a first end 654 corresponding to the first end 630 of the ceramic composite component 600 and a second end 656 positioned away from the first end 654. The ceramic core structure 612 includes a first end 660 and a second end 662 positioned away from the first end 660 and corresponding to the second end 632 of the ceramic composite component 600. As Figure 13 shown, the surfaces 640 and 642 taper inwardly towards each other from the first end 654 to the second end 656, and the surfaces 650 and 652 taper inwardly towards each other in the direction extending from the first end 660 towards the second end 662.

[0113] In the illustrated embodiment, the ceramic core structure 612 includes a recess 670 extending inwardly (i.e., toward the second surface 652) from the first surface 650, and a recess 672 extending inwardly (i.e., toward the first surface 650) from the second surface 652. The recess 670 is defined by a recess surface 680 that extends from a first end 660 to a second end 662 and terminates at a recess wall 682 that extends from the recess surface 680 to the first surface 650. The recess 672 is defined by a recess surface 684 that extends from a first end 660 to a second end 662 and terminates at a recess wall 686 that extends from the recess surface 684 to the second surface 652. In an exemplary embodiment, the recess 670 and the recess 672 are formed during the additive manufacturing of the ceramic core structure 612. However, it should be understood that the recess 670 and the recess 672 can be formed by machining or other methods after the additive manufacturing process is completed. In an exemplary embodiment, the recess 670 and the recess 672 are formed such that when the ceramic core structure 612 abuts or contacts the ceramic core structure 610 (as Figure 13 shown) (e.g., where the first end 660 of the ceramic core structure 612 is positioned adjacent to or in contact with the second end 656 of the ceramic core structure 610), the corresponding recess surfaces 680 and 684 are aligned or flush with the adjacent corresponding surfaces 640 and 642 of the ceramic core structure 610.

[0114] In the illustrated embodiment, the CMC layer 620 forming the CMC panel 614 is applied and bonded to the surface 640, the recessed surface 680, and the recessed wall 682 of the ceramic core structure 610 such that the CMC layer 620 extends on its surface 640 from a first end 654 of the ceramic core structure 610 to at least a portion of the recess 670 on the recessed surface 680 and terminates within the recess 670, adjacent to or abutting the recessed wall 682. Similarly, the CMC layer 622 forming the CMC panel 616 is applied and bonded to the surface 642, the recessed surface 684, and the recessed wall 686 of the ceramic core structure 610 such that the CMC layer 622 extends on its surface 642 from the first end 654 of the ceramic core structure 610 to at least a portion of the recess 672 on the recessed surface 684 and terminates within the recess 672, adjacent to or abutting the recessed wall 686. Thus, the CMC panel 614 is assembled such that the surface 690 of the CMC panel 614 is set flush or substantially flush with the adjacent surface 650 of the ceramic core structure 612 (or otherwise forms an aerodynamic surface). Similarly, the CMC panel 616 is assembled such that the surface 692 of the CMC panel 616 is set flush or substantially flush with the adjacent surface 652 of the ceramic core structure 612 (or otherwise forms an aerodynamic surface). In other words, the recesses 670 and 672 form respective pockets for receiving at least a portion of the corresponding CMC panels 614 and 616 therein. In an exemplary embodiment, the solid core structure (i.e., the ceramic core structure 612) at the edges of the ceramic composite component 600 provides better integrity during the laying of the CMC panels 614 and 616. Additionally, the solid core structure (i.e., the ceramic core structure 612) results in less final machining at the edges of the ceramic composite component 600 and provides better corrosion resistance at such edges.

[0115] In an exemplary embodiment, the CMC layers 620 and 622 may be applied or laid symmetrically (e.g., 0°, 90°, 90°, 0° fiber orientation relative to each other or relative to a particular reference frame) to minimize or eliminate warping or to provide structural integrity in a particular direction. However, it should be understood that the CMC layers 620 and 622 may have other laying orientations.

[0116] The assembly of the ceramic composite component 600 is accomplished by bonding the ceramic core structure 610 to the ceramic core structure 612 and applying the CMC layers 620 and 622 to the ceramic core structure 610 and the ceramic core structure 612, as described above. For ease of description and illustration, Figure 13 the flexible matrix material 490 ( Figure 12 ) is not depicted. However, it should be understood that the flexible matrix material 490 ( Figure 12) can be used to bond the ceramic core structures 610, 612 and the CMC panels 614 and 616 to each other. In an exemplary embodiment, the flexible matrix material 490( Figure 12 ) can be applied to one or more interfaces where the ceramic core structure 610, the ceramic core structure 612 and the CMC panels 614 and 616 are adjacent to or abut against each other. Thus, in an exemplary embodiment, the flexible matrix material 490( Figure 12 ) can be applied between the first end 660 of the ceramic core structure 612 and the second end 656 of the ceramic core structure 610, on the surfaces 640 and 642 between the ceramic core structure 610 and the respective CMC layers 620 and 622, and on the groove surfaces 680 and 684 between the ceramic core structure 612 and the respective CMC layers 620 and 622. The assembled CMC panels 614 and 616, the ceramic core structure 610 and the ceramic core structure 612 can then undergo heat treatment, such as curing or burnout, and subsequent chemical treatment, such as melt infiltration with silicon, to obtain the ceramic composite component 600.

[0117] Figure 14 is a schematic view of another exemplary ceramic composite component 700 according to an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 700 can be formed similar to the ceramic composite component 600( Figure 13 ), including the ceramic core structure 610, the ceramic core structure 612 and the CMC panels 614 and 616. In Figure 14 , the ceramic composite component 700 includes a cooling channel 702 extending from the first end 654 of the ceramic core structure 610 to the second end 662 of the ceramic core structure 612. In an exemplary embodiment, the cooling channel 702 includes an opening or hole that extends through a substantially mid-plane location 704 of the ceramic composite component 700, which is equidistant from the CMC panel 614 and the CMC panel 616 as the cooling channel 702 extends from the first end 654 to the second end 662. As described above in connection with the ceramic core structure 204( Figure 4-9 ), the ceramic core structure 610 can include cooling features (such as the holes 280) in the ceramic core structure 610, and the cooling features exit through the edge (such as defined by the ceramic core structure 612) of the ceramic composite component 700 via the cooling channel 702.

[0118] Figure 15 is a schematic view of another exemplary ceramic composite component 800 according to an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 800 can be formed similar to the ceramic composite component 600( Figure 13 ), including the ceramic core structure 610, the ceramic core structure 612 and the CMC panels 614 and 616. In Figure 15In [the figure], the ceramic composite component 800 includes one or more cooling channels 802 that extend inwardly through respective CMC panels 614 and 616 and into the ceramic core structure 610. In an exemplary embodiment, the cooling channels 802 include openings or holes that extend through the respective CMC panels 614 and 616 in a direction toward the first end 654 of the ceramic core structure 610. In an exemplary embodiment, the cooling channels 802 are disposed at an orientation or direction that forms an acute angle between the centerline of the respective cooling channel 802 and the respective CMC panel 614 or 616 facing the first end 654 of the ceramic core structure 610. However, it should be understood that the angular orientation of the cooling channels 802 relative to the CMC panels 614 and 616 can be configured in other ways. As described above in connection with the ceramic core structure 204 ( Figure 4-9 ), the ceramic core structure 610 can include cooling features (e.g., holes 280) in the ceramic core structure 610 that exit through the outer surface of the ceramic composite component 800 via the cooling channels 802.

[0119] Figure 16 is a schematic view of another exemplary ceramic composite component 900 according to an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 900 can be formed similar to the ceramic composite component 600 ( Figure 13 ), including a ceramic core structure 902, where CMC panels 904 and CMC panel 906 are bonded to the ceramic core structure 902. The ceramic core structure 902 and the CMC panels 904 and 906 can be formed similar to the respective ceramic core structure 610 ( Figure 13-15 ) and the CMC panels 614 and 616 ( [[ID= ). Similar to the ceramic composite component 600 ( ​ ), the ceramic composite component 900 has a tapered configuration such that the ceramic core structure 902 and the CMC panels 904 and 906 taper inwardly from the first end 908 of the ceramic composite component 900 toward the second end 910 of the ceramic composite component 900. In the illustrated embodiment, the CMC layer forming the CMC panel 904 extends from the first end 908 to the second end 910 on the surface 912 of the ceramic core structure 902, and the CMC layer forming the CMC panel 906 extends from the first end 908 to the second end 910 on the surface 914 of the ceramic core structure 902. In the illustrated embodiment, the CMC panels 904 and 906 merge and are bonded to each other at the second end 910. In an exemplary embodiment, the CMC panels 904 and 906 are pressed together or otherwise in contact with each other at the second end 910.

[0120] ​Schematic of another exemplary ceramic composite component 1000 according to an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 1000 may be similar to the ceramic composite component 600 including a ceramic core structure 610 ( ​ ) but includes a ceramic core structure 1002 instead of the ceramic core structure 612 ( ​ ). The ceramic core structure 1002 may be formed similar to the ceramic core structure 612 ( ​ ) but without the grooves 670 ( ​ ) and the grooves 672 ( ​ ). The ceramic core structure 1002 is bonded to the ceramic core structure 610 of the ceramic composite component 600 in a manner similar to that in which the ceramic core structure 612 ( ​ ) is bonded to the ceramic core structure 610 of the ceramic composite component 600 ( ​ ).

[0121] In the illustrated embodiment, the ceramic composite component 1000 further includes CMC panels 1004 and 1006. The CMC panels 1004 and 1006 may be formed similar to the CMC panels 614 and 616 ( ​ ). Similar to the ceramic composite component 600 ( ​ ), the ceramic composite component 1000 has a tapered configuration such that the ceramic core structure 610, the ceramic core structure 1002, and the CMC panels 1004 and 1006 are tapered inward from the first end 1008 of the ceramic composite component 1000 toward the second end 1010 of the ceramic composite component 1000. Similar to the ceramic composite component 900 ( ​ ), the CMC panels 1004 and 1006 merge and are bonded to each other at the second end 1010. In an exemplary embodiment, the CMC panels 1004 and 1006 are pressed together or otherwise in contact with each other at the second end 1010.

[0122] In an exemplary embodiment, the CMC layer forming the CMC panel 1004 extends on the surface 640 of the ceramic core structure 610 and the surface 1012 of the ceramic core structure 1002 such that the CMC panel 1004 extends from the first end 1008 to the second end 1010 of the ceramic composite component 1000. Similarly, the CMC layer forming the CMC panel 1006 extends on the surface 642 of the ceramic core structure 610 and the surface 1014 of the ceramic core structure 1002 such that the CMC panel 1006 extends from the first end 1008 to the second end 1010 of the ceramic composite component 1000. In the illustrated embodiment, similar to the ceramic composite component 902 ( ​ ), the CMC panels 1004 and 1006 are pressed together or otherwise in contact with each other at the second end 1010.

[0123] ​ is a schematic view of another exemplary ceramic composite component 1100 according to an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 1100 may be formed similar to the ceramic composite component 1000 ( ​ ), including a ceramic core structure 610, a ceramic core structure 1002, and CMC panels 1004 and 1006. In the illustrated embodiment, the ceramic composite component 1100 includes a tapered configuration (similar to the ceramic composite component 1000 ( ​ )) such that the ceramic core structure 610, the ceramic core structure 1002, and the CMC panels 1004 and 1006 taper inwardly from a first end 1102 of the ceramic composite component 1100 to a second end 1104 of the ceramic composite component 1100. In the illustrated embodiment, the ceramic core structure 1002 includes a first end 1106 bonded to the ceramic core structure 610 and a second end 1108 correspondingly positioned to coincide with the second end 1104 of the ceramic composite component 1100. In the illustrated embodiment, the CMC panels 1004 and 1006 end or terminate at the second end 1104 of the ceramic composite component 1100 at a position corresponding to the second end 1108 of the ceramic core structure 1002.

[0124] ​ is a schematic view of another exemplary ceramic composite component 1200 according to an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 1200 may be formed similar to the ceramic composite component 1100 ( ​ ), including a ceramic core structure 610, a ceramic core structure 1002, and CMC panels 1004 and 1006. In the illustrated embodiment, the ceramic composite component 1200 includes a tapered configuration (similar to the ceramic composite component 1100 ( ​ )) such that the ceramic core structure 610, the ceramic core structure 1002, and the CMC panels 1004 and 1006 taper inwardly from a first end 1202 of the ceramic composite component 1200 to a second end 1204 of the ceramic composite component 1100. In the illustrated embodiment, the CMC panels 1004 and 1006 end or terminate at the second end 1204 of the ceramic composite component 1200 such that at least a portion of one of the CMC panels 1004 or 1006 overlaps or laps over at least a portion of the other of the CMC panels 1004 or 1006. For example, in the illustrated embodiment, a portion 1206 of the CMC panel 1004 overlaps or laps over a portion 1208 of the CMC panel 1006 at the second end 1204 of the ceramic composite component 1100.

[0125] ​FIG. is a schematic view of another exemplary ceramic composite component 1300 according to an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 1300 may be formed similar to the ceramic composite component 1000 ( ​ ). For example, the ceramic composite component 1300 includes a ceramic core structure 1302, a ceramic core structure 1304, and CMC panels 1306 and 1308. The ceramic core structure 1302 may be formed similar to the ceramic core structure 610 ( ​ ), the ceramic core structure 1304 may be formed similar to the ceramic core structure 612 ( ​ ) or the ceramic core structure 1002 ( ​ ), and the CMC panels 1306 and 1308 may be formed similar to the CMC panels 614 and 616 ( ​ ) or the CMC panels 904 and 906 ( ​ ) or the CMC panels 1004 and 1006 ( ​ ).

[0126] In the illustrated embodiment, the ceramic composite component 1300 has a first end 1310 and a second end 1312. Similar to the ceramic composite components 600, 900, 1000, 1100, and 1200 ( ​ ), the ceramic composite component 1300 includes a tapered configuration such that the ceramic core structure 1302, the ceramic core structure 1304, and the CMC panels 1306 and 1308 taper inwardly towards each other from the first end 1310 towards the second end 1312. In the illustrated embodiment, the ceramic core structure 1302 includes a first end 1314 that coincides with the first end 1310 of the ceramic composite component 1300, and a second end 1316 that is positioned away from the first end 1314 towards the second end 1312. The ceramic core structure 1304 includes a first end 1318 that is positioned adjacent to or abuts the second end 1316 of the ceramic core structure 1302, and a second end 1320 that is positioned away from the first end 1318 towards the second end 1312.

[0127] In the illustrated embodiment, the ceramic composite component 1300 further includes a CMC filler sheet 1322. In an exemplary embodiment, the CMC filler sheet 1322 is disposed between portions of the CMC panels 1306 and 1308 that extend beyond the second end 1320 of the ceramic core structure 1304. In other words, portions 1324 of the CMC panel 1306 and portions 1326 of the CMC panel 1308 both extend beyond the second end 1320 of the ceramic core structure 1304 to the second end 1312 of the ceramic composite component 1300. The CMC filler sheet 1322 is positioned adjacent to or abuts the second end 1320 of the ceramic core structure 1304 and terminates away from the second end 1320 of the ceramic core structure 1304, coinciding with the ends of the CMC panels 1306 and 1308 at the second end 1312 of the ceramic composite component 1300. The CMC filler sheet 1322 may be formed similar to the CMC panels 1306 and 1308 such that the CMC filler sheet 1322 is formed of a number of CMC layers.

[0128] ​ is a schematic view of another exemplary ceramic composite component 1400 in accordance with an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 1400 may be formed similar to the ceramic composite component 1300 ( ​ )). In an exemplary embodiment, the ceramic composite component 1400 includes a ceramic core structure 1302, a ceramic core structure 1304, and CMC panels 1306 and 1308.

[0129] In the illustrated embodiment, the ceramic composite component 1400 has a first end 1410 and a second end 1412. Similar to the ceramic composite components 600, 900, 1000, 1100, and 1200 ( ​ ), the ceramic composite component 1400 includes a tapered configuration such that the ceramic core structure 1302, the ceramic core structure 1304, and the CMC panels 1306 and 1308 are tapered inwardly towards each other from the first end 1410 towards the second end 1412. In the illustrated embodiment, the CMC panels 1306 and 1308 terminate at the second end 1412 that coincides with the second end 1320 of the ceramic core structure 1304, thereby exposing at least a portion of the ceramic core structure 1304 at the second end 1412.

[0130] ​ is a schematic view of another exemplary ceramic composite component 1500 in accordance with an embodiment of the present disclosure. In an exemplary embodiment, the ceramic composite component 1500 may be formed similar to the ceramic composite component 1300 ( ​ )). In an exemplary embodiment, the ceramic composite component 1500 includes a ceramic core structure 1302, a ceramic core structure 1304, CMC panels 1306 and 1308, and a CMC filler sheet 1322.

[0131] In the illustrated embodiment, the ceramic composite component 1500 has a first end 1510 and a second end 1512. Similar to the ceramic composite components 600, 900, 1000, 1100, 1200, 1300, and 1400( ​ ), the ceramic composite component 1500 includes a tapered configuration such that the ceramic core structures 1302, 1304, and the CMC panels 1306 and 1308 taper inwardly towards each other from the first end 1510 towards the second end 1512. In the illustrated embodiment, the CMC panels 1306 and 1308 end or terminate at the second end 1512 of the ceramic composite component 1500 such that at least a portion of one of the CMC panels 1306 or 1308 overlaps or laps over at least a portion of the other of the CMC panels 1306 or 1308. For example, in the illustrated embodiment, a portion 1514 of the CMC panel 1306 overlaps or laps over a portion 1516 of the CMC panel 1308 at the second end 1512 of the ceramic composite component 1500.

[0132] Although ​ not shown in the illustrated embodiment, it should be understood that ​ each corresponding ceramic composite component of ​ may also include one or more CMC structures bonded to the corresponding ceramic core structure. For example, ​ the ceramic composite component 600 of ​ may have a CMC structure 206( 5 and 12) bonded to an interior portion of the ceramic core structure 610( ​ ), similar to the ceramic composite component 200( ​ ). Thus, it should be understood that the CMC structure 206( 5 and 12) may be included in each of the corresponding ceramic composite components 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, and 1500 similar to the ceramic composite component 200( ​ ). ​ is a schematic view of another exemplary ceramic composite component 1600 in accordance with an embodiment of the present disclosure. In the illustrated embodiment, the ceramic composite component 1600 includes a CMC structure 1602, a ceramic core cap 1604, and CMC panels 1608 and 1610. The CMC panels 1608 and 1610 may be formed similar to the CMC panels 614 and 616(

[0133] ​ ). The CMC structure 1602 includes a number of CMC layers 1612 and may be formed similar to the CMC panels 614 and 616( ​ )​ ) formed such that a certain number of CMC layers 1612 are subjected to a heat treatment, such as curing or burnout, to produce a high-carbon residue in the preform, followed by a chemical treatment, such as melt infiltration with silicon, to obtain a component formed of a CMC material having a desired chemical composition. The CMC layers 1612 can be laid out to have the geometry desired for the resulting CMC structure 1602, or the CMC structure 1602 can be cut or machined into the desired geometry after the heat treatment and chemical treatment.

[0134] In an exemplary embodiment, the ceramic core cap 1604 can be formed similar to the ceramic core structure 612 ( ​ ) formed such that the ceramic core cap 1604 includes a solid core formed by additive manufacturing using monolithic SiC. In the illustrated embodiment, the ceramic composite component 1600 has a first end 1620 and a second end 1622. Similar to the ceramic composite components 600, 900, 1000, 1100, 1200, 1300, 1400, and 1500 ( ​ ) the ceramic composite component 1600 includes a tapered configuration such that the CMC structure 1602, the ceramic core cap 1604, and the CMC panels 1608 and 1610 taper inwardly toward each other from the first end 1620 toward the second end 1622.

[0135] In the illustrated embodiment, the ceramic core cap 1604 includes arms 1630 and 1632 that form or define a V-shaped ceramic core cap 1604. In the illustrated embodiment, the arm 1630 defines an outer surface 1640 and an inner surface 1642 of the ceramic core cap 1604. The arm 1632 defines an outer surface 1644 and an inner surface 1646 of the ceramic core cap 1604. The CMC structure 1602 includes a surface 1650 and a surface 1652, each surface extending from a first end 1654 of the CMC structure 1602 to a second end 1656 of the CMC structure 1602. In the illustrated embodiment, the arms 1630 and 1632 define an acute angle relative to each other that is set to face the CMC structure 1602 such that the second end 1656 of the CMC structure 1602 is received within the V-shaped opening defined by the arms 1630 and 1632. The CMC panel 1608 defines a surface 1660, and the CMC panel 1610 defines a surface 1662.

[0136] In the illustrated embodiment, the arm 1630 is configured or shaped to have a thickness measured between an outer surface 1640 and an inner surface 1642, which thickness corresponds to the thickness of the CMC panel 1608 measured between a surface 1650 and a surface 1660. Additionally, the arm 1632 is configured or shaped to have a thickness measured between an outer surface 1644 and an inner surface 1646, which thickness corresponds to the thickness of the CMC panel 1610 measured between a surface 1652 and a surface 1662. Thus, upon assembly, the outer surface 1640 aligns with or is otherwise flush with the surface 1660, and the outer surface 1644 aligns with or is otherwise flush with the surface 1662. Accordingly, the outer surface 1640 and the surface 1660 form an aerodynamic surface, and the outer surface 1644 and the surface 1662 form an aerodynamic surface.

[0137] In an assembled configuration, the ceramic core cap 1604 is disposed on and bonded to the second end 1656 of the CMC structure 1602, and the CMC panels 1608 and 1610 are disposed on and bonded to the respective surfaces 1650 and 1652 and the respective arms 1630 and 1632. In an exemplary embodiment, the CMC panels 1608 and 1610 are disposed on the respective surfaces 1650 and 1652 such that the CMC layers 1612 forming the respective CMC panels 1608 and 1610 terminate adjacent to or abutting the respective arms 1630 and 1632. For ease of description and illustration, ​ the flexible matrix material 490 ( ​ ) is not shown. However, it should be understood that the flexible matrix material 490 ( ​ ) may be used to bond the ceramic core cap 1604, the CMC structure 1602, and the CMC panels 1608 and 1610 to each other. In an exemplary embodiment, the flexible matrix material 490 ( ​ ) may be applied to one or more interfaces where the ceramic core cap 1604, the CMC structure 1602, and the CMC panels 1608 and 1610 are adjacent to or abut each other. Thus, in an exemplary embodiment, the flexible matrix material 490 ( ​)Applied between the inner surface 1642 and the surface 1650, between the inner surface 1646 and the surface 1652, between the arm 1630 and the CMC panel 1608, between the arm 1632 and the CMC panel 1610, between the CMC panel 1608 and the surface 1650, and between the CMC panel 1610 and the surface 1652. Then, the assembled ceramic core cap 1604, the CMC structure 1602, and the CMC panels 1608 and 1610 can undergo heat treatment (such as curing or burnout) and subsequent chemical treatment (such as melt infiltration with silicon) to obtain the ceramic composite component 1600.

[0138] ​ is a schematic plan view of an exemplary ceramic composite component 2200 according to an embodiment of the present disclosure. In ​ it, the ceramic composite component 2200 is depicted in an assembled configuration, and the ceramic composite component 2200 is in the form of a fin 2202. For example, the fin 2202 can be used for ​ and ​ shown on the aircraft 10 or otherwise form part of the aircraft 10. For example, the fin 2202 can have a leading edge 2201, a trailing edge 2203, and one or more side edges 2205, 2207, and 2209. However, it should be understood that other types of control surfaces or control surface structures, or other types of structures and components can generally be formed without departing from the present disclosure. In the illustrated embodiment, the ceramic composite component 2200 includes a ceramic core structure 2204, a CMC structure 2206 bonded to the ceramic core structure 204, one or more CMC panels 2208 disposed on and bonded to the ceramic core structure 2204 and the CMC structure 2206, and one or more ceramic core structures 2220 defining one or more of its edges (such as the leading edge 2201, the trailing edge 2203, and the side edge 2205). In the illustrated embodiment, the CMC structure 2206 extends outward beyond the side edges 2207 and 2209 to facilitate coupling the fin 2202 to another structure.

[0139] In an exemplary embodiment, the ceramic core structure 2204 can be formed similarly to the ceramic core structure 204 ( ​ )). In an exemplary embodiment, the CMC structure 2206 can be formed similarly to the CMC structure 206 ( ​ , 5 and 12), the CMC structure 300 ( ​ ) or the CMC structure 390 ( ​ ). In an exemplary embodiment, one or more CMC panels 2208 can be formed similarly to the CMC panel 2208 ( ​ , 5 and 12).

[0140] ​ is taken along line 25-25 ​ is a schematic cross-sectional view of an exemplary ceramic composite component 2200. In ​ the illustrated embodiment, one or more CMC panels 2208 include CMC panel 2208A and CMC panel 2208B. CMC panel 2208A is bonded to side 2210 of ceramic core structure 2204. For purposes of illustration and clarity, side 2210 may also be referred to as top side 2210. CMC panel 2208B is bonded to side 2212 of ceramic core structure 2204. For purposes of illustration and clarity, side 2212 may also be referred to as bottom side 2212. CMC panel 2208A is also bonded to side 2214 of CMC structure 2206. For purposes of illustration and clarity, side 2214 of CMC structure 2206 may also be referred to as top side 2214 of CMC structure 2206. CMC panel 2208B is also bonded to side 2216 of CMC structure 2206. For purposes of illustration and clarity, side 2216 of CMC structure 2206 is also referred to as bottom side 2216 of CMC structure 2206. In the exemplary embodiment, ceramic core structure 2204, CMC structure 2206, and CMC panels 2208A and 2208B are assembled and bonded together to form ceramic composite component 2200, similar to how ceramic core structure 204, CMC structure 206, and CMC panel 208 are assembled and bonded together to form ceramic composite component 200, as shown and described in connection with ​ , 5 and 12

[0141] In the illustrated embodiment, ceramic composite component 2200 is configured to have one or more ceramic core structures 2220, and one or more ceramic core structures 2220 define one or more of its edges. For example, in the illustrated embodiment, leading edge 2201 and trailing edge 2203 are each configured to have corresponding ceramic core structures 2220A and 2220B. In the exemplary embodiment, corresponding ceramic core structures 2220A and 2220B are formed similar to ​ ceramic core structure 612. For example, ceramic core structures 2220A and 2220B include additively manufactured ceramic core structures 2220A and 2220B. In the exemplary embodiment, ceramic core structures 2220A and 2220B are solid ceramic core structures 2220A and 2220B. In the exemplary embodiment, ceramic core structures 2220A and 2220B are monolithic ceramic core structures 2220A and 2220B. In the exemplary embodiment, ceramic core structures 2220A and 2220B are made of Si or SiC. In the exemplary embodiment, ceramic core structures 2220A and 2220B may be similar to ceramic core structure 204(​ ) formed, but is solid and non-honeycomb in structure. Thus, in an exemplary embodiment, the ceramic core structures 2220A and 2220B can be additively manufactured as part of the ceramic core structure 2204 (e.g., the ceramic core structure 2204 is additively manufactured to integrally include the ceramic core structures 2220A and 2220B as a single, monolithic, one-piece, additively manufactured component such that the solid ceramic core structures 2220A and 2220B extend outwardly from the ceramic core structure 2204 portion to define corresponding edges). Thus, in an exemplary embodiment, the ceramic core structures 2220A and 2220B extend outwardly from the respective sides 2222 and 2224 of the ceramic core structure 2204 (e.g., the sides 2222 and 2224 represent one or more walls of the honeycomb ceramic core structure 2204) to define the respective leading edges 2201 and trailing edges 2203 of the ceramic composite component 2200. Alternatively, the ceramic core structures 2220A and 2220B can be formed separately and bonded to the ceramic core structure 2204 (e.g., separately additively manufactured and bonded to the respective sides 2222 and 2224 of the ceramic core structure 2204). Additionally, it should be understood that the ceramic core structure 2204, the ceramic core structures 2220A and 2220B, and the respective CMC panels 2208A and 2208B can be assembled or bonded together, similar to the ceramic core structure 611, the ceramic core structure 612, and the CMC panels 614 and 616 being assembled and bonded together to form the ceramic composite component 600, as ​ shown and described.

[0142] In the illustrated embodiment, the leading edge 2201 and the trailing edge 2203 are configured to have the respective ceramic core structures 2220A and 2220B. However, additionally or alternatively, the ceramic core structure 2220 can be included at other edges of the ceramic composite component 2200 or omitted at certain edges (e.g., only included on the leading edge 2201). Additionally, it should be understood that one or more edges of the ceramic composite component 2200 can be configured as ​ shown and described in any ceramic composite component embodiment of

[0143] Now referring to ​ , a flowchart outlining the steps of a method for forming a ceramic composite component (e.g., the ceramic composite component 200 ( ​ and ​ )) is provided (hereinafter referred to as "method 2600"). The method includes, at 2602, additively manufacturing a ceramic structure honeycomb core component, such as the ceramic core structure 204 ( ​)。At 2604, the additively manufactured ceramic structure honeycomb core component from step 2602 is heat treated and chemically treated (e.g., pyrolysis and melt infiltration). At 2606, the method includes laying or manufacturing a CMC structure, such as CMC structure 206( ​ and ​ (which may include manufacturing CMC structure 300( ​ ) or CMC structure 390( ​ ))). At 2608, the CMC structure manufactured at step 2606 is heat treated and chemically treated (e.g., pyrolysis and melt infiltration). At 2610, the additively manufactured ceramic structure honeycomb core component manufactured at steps 2602 and 2604 and the CMC structure manufactured at steps 2606 and 2608 can be cut or machined into a specific geometry. At 2612, a flexible matrix material (e.g., flexible matrix material 490( ​ )) is applied to various interface surfaces of the additively manufactured ceramic structure honeycomb core component and CMC structure manufactured at steps 2602 - 2610. At 2614, the method includes assembling the additively manufactured ceramic structure honeycomb core component and CMC structure manufactured at steps 2602 - 2610 with each other. In an exemplary embodiment, CMC structure 206( ​ and ​ ) is inserted into the groove portions 254( ​ and ​ ) of ceramic core structure 204( ​ and ​ ), as ​ shown. At 2616, the method includes applying a CMC layer to form one or more CMC panels on the assembled additively manufactured ceramic structure honeycomb core component and CMC structure. For example, CMC layer 500( ​ ) is applied to ceramic core structure 204( ​ ) and CMC structure 206( ​ ) to form CMC panel 208. At step 2618, the assembled CMC layer / CMC panel and the assembled additively manufactured ceramic structure honeycomb core component and CMC structure are heat treated and chemically treated (e.g., pyrolysis and melt infiltration).

[0144] Now referring to ​ , an overview is provided for forming ceramic composite components (e.g., ceramic composite components 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400 or 1500( ​Flowchart of the steps of the method (hereinafter referred to as "Method 2700"). The method includes, at 2702, additively manufacturing a ceramic core component, such as ceramic core structures 610, 902, or 1302 ( ​ and ​ ). At 2704, the ceramic core structure additively manufactured in step 2702 is heat-treated and chemically treated (e.g., pyrolysis and melt infiltration). At 2706, the method includes additively manufacturing a ceramic solid core component, such as ceramic core structures 612, 1002, or 1304 ( ​ and ​ ). At 2708, the ceramic solid core component additively manufactured in step 2706 is heat-treated and chemically treated (e.g., pyrolysis and melt infiltration). At 2710, the additively manufactured ceramic core structures manufactured in steps 2702 and 2704 and the additively manufactured ceramic solid core structures manufactured in steps 2706 and 2708 can be cut or machined into a specific geometry. At 2712, a flexible matrix material (e.g., flexible matrix material 490 ( ​ )) is applied to various interface surfaces of the additively manufactured ceramic core structures and additively manufactured ceramic solid core structures manufactured in steps 2702 - 2710.

[0145] At 2714, the method includes assembling the additively manufactured ceramic core structures and additively manufactured ceramic solid core structures manufactured in steps 2702 - 2710 with each other. In an exemplary embodiment, the ceramic core structures 610, 902, or 1302 ( ​ and ​ ) are arranged adjacent to or abutting the corresponding ceramic core structures 612, 1002, or 1304 ( ​ and ​ ), as shown in ​ and ​ . At 2716, the method includes applying a CMC layer to form one or more CMC panels on the additively manufactured ceramic core structures and additively manufactured ceramic solid core structures assembled in step 2714. For example, applying a CMC layer on the corresponding ceramic core structures 610, 902, or 1302 ( ​ and ​ ) and the corresponding ceramic core structures 612, 1002, or 1304 ( ​ and ​ ) to form the corresponding CMC panels 614, 616, 1004, 1006, 1306, or 1308, as shown in ​ and ​As shown. At step 2718, the assembled CMC layer / CMC panel, the additively manufactured ceramic core structure, and the additively manufactured ceramic solid core structure are subjected to heat treatment and chemical treatment (e.g., pyrolysis and melt infiltration).

[0146] Now refer to ​ , a flowchart outlining the steps of a method for forming a ceramic composite component (e.g., ceramic composite component 1600 ( ​ )) is provided (hereinafter referred to as "Method 2800"). The method includes, at 2802, laying a CMC layer (e.g., CMC layer 1612 ( ​ )) to form a CMC structure (e.g., CMC structure 1602 ( ​ ). At 2804, the CMC layer laid at step 2802 is subjected to heat treatment and chemical treatment (e.g., pyrolysis and melt infiltration) to form a CMC structure. At 2806, the method includes additively manufacturing a ceramic solid core structure, such as ceramic core cap 1604 ( ​ ). At 2808, the additively manufactured ceramic solid core structure from step 2806 is subjected to heat treatment and chemical treatment (e.g., pyrolysis and melt infiltration). At 2810, the CMC structure manufactured at steps 2802 and 2804 and the additively manufactured ceramic solid core structure from steps 2806 and 2808 can be cut or machined into a specific geometry. At 2812, a flexible matrix material (e.g., flexible matrix material 490 ( ​ )) is applied to the various interface surfaces of the CMC structure and the additively manufactured solid core structure manufactured at steps 2802 - 2810.

[0147] At 2814, the method includes assembling the CMC structure and the additively manufactured ceramic solid core structure manufactured at steps 2802 - 2810 with each other. In an exemplary embodiment, the CMC structure 1602 ( ​ ) is disposed within or between the arms 1630 ( ​ ) and 1632 ( ​ ) of the ceramic core cap 1604 ( ​ ), such that the second end 1656 ( ​ ) of the CMC structure 1602 ( ​ ) is set to be adjacent to or abut against the V - shaped opening of the ceramic core cap 1604 ( ​ ) defined by the arms 1630 and 1632 ( ​ ). At 2816, the method includes applying a CMC layer to form one or more CMC panels on the CMC structure assembled at step 2814. For example, a CMC layer is applied on the CMC structure 1602 ( ​ ) to form the corresponding CMC panels 1608 and 1610 (​ )。At step 2818, the assembled CMC layer / CMC panel, CMC structure, and additively manufactured ceramic solid core structure are heat treated and chemically treated (e.g., pyrolyzed and melt infiltrated) to bond the assembled CMC layer / CMC panel to the CMC structure and the additively manufactured ceramic solid core structure to each other.

[0148] Accordingly, embodiments of the present disclosure provide a ceramic composite component suitable for high temperature and high specific stiffness applications, including hypersonic aerodynamic control surfaces such as fins, flaps, ailerons, and elevons. In an exemplary embodiment, the ceramic matrix component includes one or more monolithic core structures configured to have multiple functions. A high temperature CMC layer is laminated to the monolithic core structure. The monolithic core structure can be printed or machined or manufactured by other known methods, which use monolithic ceramics as single or multi-segment cores to achieve the overall aerodynamic structure. The core or core segment can include areas or features for integration and engagement with CMC layers and components within the structure to enhance functional performance and reliability. In an exemplary embodiment, a single-piece monolithic core can include: pockets and interlocking features for internal attachment or for placement of CMC layers or CMC inserts; a leading edge with an aerodynamic shape having an internal edge for the CMC panel layer arrangement; a backbone framework of different shaped walls for managing local structural stiffness; and mating features for adapting to engagement with the monolithic ceramic core structure.

[0149] A further aspect is provided by the subject matter of the following clauses:

[0150] A ceramic composite component, comprising: a ceramic core structure having a plurality of hollow cells defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure, the second side being opposite the first side; a ceramic matrix composite (CMC) structure coupled to the ceramic core structure, the CMC structure including a plurality of CMC layers, the CMC structure being defined by a first side of the CMC structure and a second side of the CMC structure, the second side of the CMC structure being opposite the first side of the CMC structure; a first CMC panel bonded to the first side of the ceramic core structure and the first side of the CMC structure; and a second CMC panel bonded to the second side of the ceramic core structure and the second side of the CMC structure.

[0151] The ceramic composite component according to the preceding clause, wherein the CMC structure is bonded to the ceramic core structure.

[0152] The ceramic composite component according to any one of the preceding clauses, wherein the CMC structure is bonded to the ceramic core structure using a flexible matrix material.

[0153] The ceramic composite component according to any one of the preceding clauses, wherein the CMC structure is bonded to at least a portion of the plurality of walls of the ceramic core structure.

[0154] The ceramic composite component according to any one of the preceding clauses, wherein the CMC structure is mechanically coupled to the ceramic core structure.

[0155] The ceramic composite component according to any one of the preceding clauses, wherein the ceramic core structure includes interlocking features that engage complementary interlocking features formed on the CMC structure.

[0156] The ceramic composite component according to any one of the preceding clauses, wherein the ceramic core structure includes a first ceramic core structure and further includes a second ceramic core structure that defines an edge of the ceramic composite component, the second ceramic core structure including a solid ceramic core structure.

[0157] The ceramic composite component according to any one of the preceding clauses, wherein the first CMC panel is bonded to at least a first portion of the second ceramic core structure, and wherein the second CMC panel is bonded to at least a second portion of the second ceramic core structure.

[0158] The ceramic composite component according to any one of the preceding clauses, wherein the first ceramic core structure is integrally formed with the second ceramic core structure.

[0159] The ceramic composite component according to any one of the preceding clauses, wherein at least one of the first CMC panel or the second CMC panel further defines the edge of the ceramic composite component.

[0160] The ceramic composite component according to any one of the preceding clauses, wherein the second ceramic core structure extends from the first ceramic core structure.

[0161] The ceramic composite component according to any one of the preceding clauses, wherein the second ceramic core structure is bonded to the first ceramic core structure.

[0162] The ceramic composite component according to any one of the preceding clauses, wherein the second ceramic core structure includes a tapered geometry.

[0163] The ceramic composite component according to any one of the preceding clauses, wherein the CMC structure includes a tapered geometry.

[0164] The ceramic composite component according to any one of the preceding clauses, wherein the ceramic core structure includes the first ceramic core structure, and wherein the CMC structure includes a third ceramic core structure disposed between at least a portion of the plurality of CMC layers.

[0165] The ceramic composite component according to any one of the preceding clauses, wherein the third ceramic core structure includes at least one of a solid ceramic core structure, a porous ceramic core structure, or a structured honeycomb ceramic core structure.

[0166] The ceramic composite component according to any one of the preceding clauses, wherein the first ceramic core structure is additively manufactured.

[0167] The ceramic composite component according to any one of the preceding clauses, wherein the second ceramic core structure is additively manufactured.

[0168] The ceramic composite component according to any one of the preceding clauses, wherein the third ceramic core structure is additively manufactured.

[0169] A method of forming a ceramic composite component, comprising: coupling a ceramic matrix composite (CMC) structure to a ceramic core structure, wherein the ceramic core structure includes a plurality of hollow units defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure opposite the first side, and wherein the CMC structure includes a plurality of CMC layers defining a first side of the CMC structure and a second side of the CMC structure opposite the first side of the CMC structure; bonding a first CMC panel to the first side of the ceramic core structure and the first side of the CMC structure; bonding a second CMC panel to the second side of the ceramic core structure and the second side of the CMC structure; and densifying and bonding together the first CMC panel and the second CMC panel, the ceramic core structure, and the CMC structure.

[0170] The method according to the preceding clause, further comprising additively manufacturing the ceramic core structure.

[0171] The method according to any one of the preceding clauses, further comprising applying a flexible matrix material to an interface between the ceramic core structure and the CMC structure.

[0172] The method according to any one of the preceding clauses, further comprising forming the CMC structure with another ceramic core structure disposed between at least a portion of the plurality of CMC layers.

[0173] The method according to any one of the preceding clauses, wherein the ceramic core structure includes a first ceramic core structure and further includes a second ceramic core structure extending from the first ceramic core structure and defining an edge of the ceramic composite component, the second ceramic core structure including a solid ceramic core structure, and the method further includes: bonding the first CMC panel to at least a first portion of the second ceramic core structure; and bonding the second CMC panel to at least a second portion of the second ceramic core structure.

[0174] The method according to any one of the preceding clauses, further including bonding the second ceramic core structure to the first ceramic core structure.

[0175] A ceramic composite component, comprising: a first ceramic core structure having a plurality of hollow cells defined by a plurality of walls extending from a first side of the first ceramic core structure to a second side of the first ceramic core structure, the second side being opposite to the first side; a second ceramic core structure extending from the first ceramic core structure and defining an edge of the ceramic composite component, the second ceramic core structure including a solid ceramic core structure; a first CMC panel bonded to the first side of the first ceramic core structure and at least a first portion of the second ceramic core structure; and a second CMC panel bonded to the second side of the ceramic core structure and at least a second portion of the second ceramic core structure.

[0176] A method of assembling a ceramic composite component, comprising: applying a flexible matrix material to an interface of a ceramic core structure, wherein the ceramic core structure includes a plurality of hollow cells defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure opposite to the first side; disposing a CMC structure on the interface of the ceramic core structure with the flexible matrix material therebetween, wherein the CMC structure includes a plurality of CMC layers defining a first side of the CMC structure and a second side of the CMC structure opposite to the first side of the CMC structure; disposing at least one CMC panel on the first side and the second side of the ceramic core structure and on the first side and the second side of the CMC structure; and densifying and bonding together the at least one CMC panel, the flexible matrix material, the ceramic core structure, and the CMC structure.

[0177] The method according to any one of the preceding clauses, further including additive manufacturing the ceramic core structure.

[0178] The method according to any one of the preceding clauses further comprises forming the CMC structure with another ceramic core structure disposed between at least a portion of the plurality of CMC layers.

[0179] The method according to any one of the preceding clauses further comprises forming the another ceramic core structure as at least one of a solid ceramic core structure, a porous ceramic core structure, or a structured honeycomb ceramic core structure.

[0180] The method according to any one of the preceding clauses, wherein the ceramic core structure comprises a first ceramic core structure and further comprises a second ceramic core structure adhered to the first ceramic core structure and defining an edge of the ceramic composite component, the second ceramic core structure comprising a solid ceramic core structure, and further comprising adhering the second ceramic core structure to the first ceramic core structure.

[0181] The method according to any one of the preceding clauses further comprises adhering the first CMC panel to at least a first portion of the second ceramic core structure and adhering the second CMC panel to at least a second portion of the second ceramic core structure.

[0182] The method according to any one of the preceding clauses further comprises forming the second ceramic core structure including a tapered geometry.

[0183] The method according to any one of the preceding clauses further comprises forming the ceramic core structure with interlocking features that are capable of engaging complementary interlocking features formed on the CMC structure.

[0184] The method according to any one of the preceding clauses further comprises forming the ceramic core structure with at least one hole extending from a first unit of the plurality of hollow units to a second unit of the plurality of hollow units.

[0185] A ceramic composite component, comprising: a first ceramic core structure defined by a first side extending from a first end of the first ceramic core structure to a second end of the first ceramic core structure, and wherein the first ceramic core structure is defined by a second side extending from the first end to a second end opposite the first side; a second ceramic core structure bonded to the second end of the first ceramic core structure, the second ceramic core structure defining a first groove positioned adjacent to the first side of the first ceramic core structure and a second groove positioned adjacent to the second side of the first ceramic core structure; a first CMC panel disposed on the first side of the first ceramic core structure and terminating within the first groove of the second ceramic core structure; and a second CMC panel disposed on the second side of the first ceramic core structure and terminating within the second groove of the second ceramic core structure.

[0186] The ceramic composite component according to any one of the preceding clauses, wherein the first ceramic core structure comprises a tapered geometry.

[0187] The ceramic composite component according to any one of the preceding clauses, wherein the second ceramic core structure comprises a tapered geometry.

[0188] The ceramic composite component according to any one of the preceding clauses, wherein the second ceramic core structure is defined by a first side of the second ceramic core structure and a second side opposite the first side, wherein the first groove is recessed from the first side of the second ceramic core structure, and the second groove is recessed from the second side of the second ceramic core structure, and wherein the first CMC panel is aligned with the first side of the second ceramic core structure, and the second CMC panel is aligned with the second side of the second ceramic core structure.

[0189] The ceramic composite component according to any one of the preceding clauses, further comprising at least one hole extending through at least one of the first CMC panel or the second CMC panel from within the first ceramic core structure.

[0190] The ceramic composite component according to any one of the preceding clauses, further comprising at least one hole extending through the second ceramic core structure from within the first ceramic core structure.

[0191] The ceramic composite component according to any one of the preceding clauses, wherein the first ceramic core structure comprises a plurality of hollow units defined by a plurality of walls, and wherein the second ceramic core structure comprises a solid ceramic core structure.

[0192] The ceramic composite component according to any one of the preceding clauses, wherein the plurality of hollow units include a first unit and a second unit, the first unit and the second unit being defined by a first wall among the plurality of walls therebetween, wherein the first wall includes at least one hole extending from the first unit to the second unit.

[0193] A ceramic composite component, comprising: a first ceramic core structure having a plurality of hollow units defined by a plurality of walls, wherein the first ceramic core structure is defined by a first side extending from a first end of the first ceramic core structure to a second end of the first ceramic core structure, and wherein the first ceramic core structure is defined by a second side opposite to the first side, the second side extending from the first end to the second end; a second ceramic core structure bonded to the second end of the first ceramic core structure, the second ceramic core structure being defined by a third side aligned with the first side, the second ceramic core structure being defined by a fourth side aligned with the second side; a first CMC panel extending over and bonded to the first side and the third side; and a second CMC panel extending over and bonded to the second side and the fourth side.

[0194] The ceramic composite component according to any one of the preceding clauses, wherein the second ceramic core structure includes a first end and a second end, the first end of the second ceramic core structure being bonded to the second end of the first ceramic core structure.

[0195] The ceramic composite component according to any one of the preceding clauses, wherein the first CMC panel and the second CMC panel each terminate at the second end of the second ceramic core structure.

[0196] The ceramic composite component according to any one of the preceding clauses, wherein the first CMC panel overlaps the second CMC panel at the second end of the second ceramic core structure.

[0197] The ceramic composite component according to any one of the preceding clauses, further comprising a CMC filler sheet bonded to the second end of the second ceramic core structure and disposed between the first CMC panel and the second CMC panel.

[0198] This written description uses examples to disclose the present disclosure, including the best mode, and also enables any person skilled in the art to practice the present disclosure, including making and using any device or system and performing any incorporated method. The patentable scope of the present disclosure is defined by the claims and may include other examples that occur to those skilled in the art. If these other examples include structural elements that are identical to the literal language of the claims, or if they include equivalent structural elements that are not materially different from the literal language of the claims, then these other examples are intended to fall within the scope of the claims.

Claims

1. A ceramic composite component, characterized in that, Comprising: A ceramic core structure having a plurality of hollow cells defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure, the second side being opposite the first side; A ceramic matrix composite (CMC) structure coupled to the ceramic core structure, the CMC structure including a plurality of CMC layers, the CMC structure being defined by a first side of the CMC structure and a second side of the CMC structure, the second side of the CMC structure being opposite the first side of the CMC structure; A first CMC panel adhered to the first side of the ceramic core structure and the first side of the CMC structure; And A second CMC panel adhered to the second side of the ceramic core structure and the second side of the CMC structure.

2. The ceramic composite component according to claim 1, wherein Wherein, The CMC structure is adhered to the ceramic core structure.

3. The ceramic composite component according to claim 1, characterized in that, Wherein, The CMC structure is adhered to the ceramic core structure using a flexible matrix material.

4. The ceramic composite component according to claim 1, wherein Wherein, The CMC structure is adhered to at least a portion of the plurality of walls of the ceramic core structure.

5. The ceramic composite component according to claim 1, characterized in that Wherein, The CMC structure is mechanically coupled to the ceramic core structure.

6. The ceramic composite component according to claim 1, wherein Wherein, The ceramic core structure includes a first ceramic core structure and further includes a second ceramic core structure defining an edge of the ceramic composite component, the second ceramic core structure including a solid ceramic core structure.

7. The ceramic composite component according to claim 6, wherein, Wherein, The first CMC panel is adhered to at least a first portion of the second ceramic core structure, and wherein the second CMC panel is adhered to at least a second portion of the second ceramic core structure.

8. The ceramic composite component according to claim 7, characterized in that, Wherein, At least one of the first CMC panel or the second CMC panel further defines the edge of the ceramic composite component.

9. The ceramic composite component according to claim 6, characterized in that, Wherein, The second ceramic core structure extends from the first ceramic core structure.

10. The ceramic composite component according to claim 9, characterized in that, Wherein, The first ceramic core structure and the second ceramic core structure are integrally formed.

Images