Ceramic matrix composite material structures and methods for their manufacture
Patent Information
- Application Number
- ES2024202443T
- Authority / Receiving Office
- ES · ES
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2023-11-29
- Filing Date
- 2024-09-25
- Publication Date
- 2026-09-15
- Estimated Expiration
- 2044-09-25
Smart Images
Figure 00000013_0000 
Figure 00000013_0001 
Figure 00000013_0002
Abstract
Description
Ceramic matrix composite material structures and methods for their manufacture This application relates to composite structures and, more particularly, to ceramic matrix composite structures and methods for manufacturing them. Ceramic matrix composites have a different stickiness and texture than polymer matrix composites, requiring distinct processing methods. The ceramic fibers in ceramic matrix composites are more brittle and rigid than the carbon fibers in polymer matrix composites. These more brittle and rigid fibers, along with a different organic resin composition, necessitate different processing methods during the fabrication of ceramic matrix composite structures. A typical ceramic matrix composite structure is manufactured using a manual coating process. One drawback of using a manual coating process to manufacture a ceramic matrix composite structure is the variability in the quality and consistency of the resulting structure. Therefore, manual inspection and rework are often necessary. Another disadvantage is that the manual coating process is time-consuming and requires skilled technicians. The overall result is an increased cycle time and higher labor costs for manufacturing the ceramic matrix composite structure. The summary of WO2014 / 094903 states the following: "A tissue handling apparatus includes a placement table, a mold adjacent to the placement table, and a tissue handling assembly suspended above the placement table and the mold. The tissue handling assembly is adapted to transfer at least one tissue shape from the placement table to the mold. The tissue handling array includes a plurality of attractors in an attractor array. An orientation of the tissue handling assembly is alterable with respect to at least one of the placement table and the mold, such that the at least one tissue shape is positionable in the mold in a predetermined orientation." Despite the progress already made, experts in the technique continue with research and development efforts in the field of manufacturing ceramic matrix composite material structures. In one aspect, an electronically controlled method is provided for manufacturing a non-polymeric structure with a desired shape. The electronically controlled method comprises transporting a stack comprising at least a first non-polymeric layer and a second non-polymeric layer from a surface at a first location to a tool surface at a second location, which is different from the first location, to enable the stack of at least the first non-polymeric layer and the second non-polymeric layer to be manufactured as the non-polymeric structure with the desired shape at the second location. In another aspect, an electronically controlled method is provided for manufacturing a ceramic matrix composite structure with a desired shape. The electronically controlled method comprises processing a plurality of ceramic matrix composite layers at a first location to form a stack of the plurality of layers. The electronically controlled method also comprises transporting the stack of the plurality of layers of ceramic matrix composite from the first location to a second location located away from the first. The electronically controlled method further comprises processing the stack of the plurality of layers of ceramic matrix composite at the second location to give the ceramic matrix composite structure the desired shape.This aspect can be combined with the aspect described above or it can be provided as a separate aspect that is independent of the aspect described above. In another aspect, an electronically controlled method is provided for fabricating a ceramic matrix composite structure of a desired shape. The electronically controlled method comprises picking up a first layer of ceramic matrix composite material sandwiched between a first lower support layer and a first upper support layer, and placing the first layer of ceramic matrix composite material onto a table surface at a first location. The electronically controlled method also comprises peeling the first upper support layer from the top surface of the first ceramic matrix composite layer, and picking up a second ceramic matrix composite layer sandwiched between a second lower support layer and a second upper support layer.The electronically controlled method further comprises peeling the second lower support film from a lower surface of the second ceramic matrix composite layer, and placing the lower surface of the second ceramic matrix composite layer onto the upper surface of the first ceramic matrix composite layer to form a stack of at least the first and second ceramic matrix composite layers.The electronically controlled method also comprises transporting the stack of at least the first and second layers of ceramic matrix composite material from the table surface at the first location to a tool surface at a second location that is different from the first location, to allow the stack of at least the first and second layers of ceramic matrix composite material to be fabricated as the ceramic matrix composite structure with the desired shape at the second location. This aspect may be combined with one or both of the aspects described above or may be provided as a separate aspect that is independent of both of the aspects described above. Other aspects will become evident from the following detailed description, the accompanying drawings, and the attached claims. Figure 1 is a schematic block diagram of an apparatus for fabricating a ceramic matrix composite material structure according to one embodiment. Figure 2A is an elevated view of a first non-polymeric layer processed to obtain a ceramic matrix composite material structure. Figure 2B is an elevated view of a second non-polymeric layer being processed with the first non-polymeric layer of Figure 2A to obtain a ceramic matrix composite material structure. Figures 3A–3M are elevation views showing certain components of the fabrication apparatus in Figure 1 in different positions during the fabrication of a ceramic matrix composite structure. Figure 4A is an enlarged elevation view of an example of layer stacking of ceramic matrix composite material according to Figures 3A–3F. Figure 4B is an enlarged elevated view of an example of compacted stacking of ceramic matrix composite material layers according to Figures 3G-3I. Figure 5 is an enlarged elevated view of an example of a ceramic matrix composite material structure fabricated according to Figures 3J-3M. Figure 6 is a general flow diagram representing an example of a manufacturing method for a ceramic matrix composite material structure according to one embodiment. Figure 7 is a flowchart that represents an example of an electronically controlled method for fabricating a non-polymeric structure with a desired shape according to an embodiment. Figure 8 is a flowchart depicting an example of an electronically controlled method for fabricating a ceramic matrix composite material structure with a desired shape according to another embodiment. Figure 9 is a flowchart depicting an example of an electronically controlled method for fabricating a ceramic matrix composite material structure with a desired shape according to another embodiment. Figure 10 is a flowchart of an aircraft manufacturing and servicing methodology. Figure 11 is a block diagram of an aircraft. This application relates to ceramic matrix composite structures and methods for manufacturing them. The specific construction of the ceramic matrix composite structures and the methods for their manufacture, as well as the industry in which the structures and methods are applied, may vary. It should be understood that the following disclosure provides a number of embodiments or examples for implementing different attributes of various embodiments. Specific examples of components and arrangements are described to simplify this disclosure. These are merely examples and are not intended to be limiting. As an example, the following disclosure describes ceramic matrix composite structures and methods for manufacturing at least one aircraft component, such as an aircraft exhaust structure. The ceramic matrix composite structures and manufacturing methods can be applied by an original equipment manufacturer (OEM) in compliance with commercial, military, and aerospace regulations. It is conceivable that the disclosed ceramic matrix composite structures and manufacturing methods could be applied in many other ceramic matrix composite manufacturing industries. With reference to Figure 1, a schematic block diagram of an apparatus 100 for manufacturing a ceramic matrix composite material structure according to one embodiment is illustrated. The apparatus 100 comprises a table 102 with a table surface 104 at a first location, and a tool 110 with a tool surface 112 at a second location that is different (i.e., remote) from the first location. The table surface 104 may comprise a releasable or electrostatic vacuum capable of holding a first layer of material in position on the table surface 104, while subsequent layers of material are placed and compacted onto that first layer. By way of example, the table surface 104 may comprise a valve-operated vacuum table. The tool surface 112 has optional steps 114 in the vicinity of the tool perimeter 110.The apparatus 100 further comprises a series of mechanisms including a detachment mechanism 120, a collection mechanism 130, and a vacuum forming mechanism 140. The detachment mechanism 120 is located at the first location where the table 102 is located. The pickup mechanism 130 is a gripping end effector for picking up and placing a sheet (e.g., a layer) of material onto surface 104 of table 102 or surface 112 of tool 110. The pickup mechanism 130 may comprise electrostatic grippers or vacuum grippers, for example. The pickup mechanism 130 is movable in opposite directions indicated by arrows X and Y between the first location where table 102 is located and the second location where tool 110 is located. The vacuum forming mechanism 140 includes a vacuum membrane 142 and is located at the second location where tool 110 is located. The structure and operation of the peeling, pickup, and vacuum forming mechanisms are known and conventional and will therefore not be described. Although Figure 1 shows only one collection mechanism (i.e., collection mechanism 130), it is conceivable that two collection mechanisms could be provided, one associated with the first location and the other with the second. It is also conceivable that two release mechanisms could be provided, one associated with the first location and the other with the second. For simplicity and ease of explanation, only one collection mechanism and one release mechanism, as shown in Figure 1, will be used and described herein. With reference to Figure 2A, an elevated view of a first non-polymeric layer 210 processed to provide a ceramic matrix composite structure is illustrated. The first non-polymeric layer 210 includes a first ceramic matrix composite layer 212 sandwiched between a first upper support layer 211 and a first lower support layer 213. The first ceramic matrix composite layer 212 has first fiber reinforcements 214 oriented in a first direction shown as arrow A in Figure 2A. The first fiber reinforcements 214 comprise ceramic fibers, and the matrix is a ceramic base material. Alternatively, the first ceramic matrix composite layer 212 may comprise a ceramic matrix composite layer having a fabric pre-impregnated with a matrix material, such as Cf / Si or SiCf / SiC, for example. The first layer of ceramic matrix composite material 212 is a non-polymeric material with a viscosity between approximately 300 Pa·s and 700 Pa·s (3000 Poise and 7000 Poise). The tackiness of the first layer of ceramic matrix composite material 212 can vary depending on the amount of water it contains. Alternatively, the tackiness of the first layer of ceramic matrix composite material 212 can vary depending on the amount of solvent (e.g., non-aqueous) it contains. Other aqueous and non-aqueous-based compounds are possible. The weight of the first layer of ceramic matrix composite material 212 for a given volume is less than the weight of an equivalent volume of metallic material, such as steel. With reference to Figure 2B, an elevated view is illustrated of a second non-polymeric layer 220 being processed with the first non-polymeric layer 210 of Figure 2A to provide a ceramic matrix composite material structure. The second non-polymeric layer 220 includes a second ceramic matrix composite layer 222 sandwiched between a second upper support layer 221 and a second lower support layer 223. The second ceramic matrix composite layer 222 has fiber reinforcements 224 oriented in a second direction shown as arrow B in Figure 2B. The second direction B of the second fiber reinforcements 224 is transverse (e.g., perpendicular) to the first direction A of the first fiber reinforcements 214. It is conceivable that the second direction B of the second fiber reinforcements 224 is not transverse (e.g., parallel) to the first direction A of the first fiber reinforcements 214.The second fiber reinforcements 224 comprise ceramic fibers, and the matrix is a ceramic-based material. Alternatively, the second ceramic matrix composite layer 222 may comprise a ceramic matrix composite layer having a fabric pre-impregnated with a matrix material, such as Cf / Si or SiCf / SiC, for example. The second layer of ceramic matrix composite material 222 is a non-polymeric material with a viscosity between approximately 300 Pa·s and 700 Pa·s (3000 Poise and 7000 Poise). The tackiness of the second layer of ceramic matrix composite material 222 can vary depending on the amount of water it contains. Alternatively, the tackiness of the second layer of ceramic matrix composite material 222 can vary depending on the amount of solvent (e.g., non-aqueous) it contains. Other aqueous and non-aqueous-based compounds are possible. The weight of the second layer of ceramic matrix composite material 222 for a given volume is less than an equivalent volume of metallic material, such as steel. With reference to Figures 3A–3M, elevated views show certain components of the fabrication apparatus 100 of Figure 1 in different positions during the fabrication of a ceramic matrix composite structure. From a general perspective, Figures 3A–3F show the first non-polymeric layer 210 and the second material layer 220 of Figures 2A and 2B being processed to provide a stack 400 (shown in Figure 4A) comprising the second upper support layer 221, the first and second ceramic matrix composite layers 212, 222, and the first lower support layer 213. Figures 3G–3I show the stack 400 being processed to transport it from table 102 at the first location to tool 110 at the second location.Figures 3J-3M show the stack 400 being processed to provide a compacted stack 450 (shown in Figure 4B) and thereby to fabricate a ceramic matrix composite material structure (shown in Figure 5) comprising the first and second layers of ceramic matrix composite material 212, 222 formed as shown in Figure 5. As shown in Figure 3A, the pickup mechanism 130 is picking up the first non-polymeric layer 210 (Figure 2A) comprising the first ceramic matrix composite layer 212, the first lower support layer 213, and the first upper support layer 211. As shown in Figure 3B, the pickup mechanism 130 lowers the first non-polymeric layer 210 onto the table 102. The pickup mechanism 130 is subsequently lifted from the table 102, and the peeling mechanism 120 removes the first upper support layer 211, as shown in Figure 3C, leaving the first ceramic matrix composite layer 212 and the first lower support layer 213 on the table 102.Subsequently, after the peeling mechanism 120 removes the second lower support film 223 from the second material layer 220, the second ceramic matrix composite material layer 222 together with the second upper support film 221 is placed on the table 102, as shown in Figure 3D. Thus, the collection mechanism 130 in Figure 3D holds the second ceramic matrix composite layer 222 and the second upper support layer 221. As shown in Figure 3E, the pickup mechanism 130 lowers the second layer of ceramic matrix composite material 222 and the second upper support layer 221 onto the first layer of ceramic matrix composite material 212 already on the table 102 to compact the first and second layers of ceramic composite material 212 together. The pickup mechanism 130 is then lifted from the table 102 as shown in Figure 3F, leaving behind the stack 400 (Figure 4A) comprising the second ceramic matrix composite layer 222 and the second upper support layer 221 on top of the first ceramic matrix composite layer 212 and the first lower support layer 213. Sufficient pressure is applied to the stack 400 to allow handling, but not so much as to prevent the stack 400 from forming into the final tool contour. Subsequently, the pickup mechanism 130 is lowered onto stack 400 as shown in Figure 3G to lift stack 400 from table 102 as shown in Figure 3H. The pickup mechanism 130 is then moved from the first location where table 102 is located, as shown in Figure 3H, to the second location where tool 110 is located, as shown in Figure 3I. After removing the first bottom support film 213 (which is optional at this stage of manufacturing), the pickup mechanism 130 then lowers the stack 400 (minus the first bottom support film 213 if removed) onto tool 110, as shown in Figure 3J. After lifting the pickup mechanism 130, as shown in Figure 3K, the vacuum membrane 142 (Figure 1) is placed over tool 110, which is referred to as "encasing" the stack 400 with the vacuum membrane 142. The vacuum forming mechanism 140 applies a vacuum to compact the stack 400 of Figure 4A (minus the first bottom support film 213 if removed) to the shape of tool 110, providing a compacted stack 450, as shown in Figure 3L. The compacted stack 450 is shown enlarged in Figure 4B. After the stack 400 of Figure 4A (less the first lower support film 213 if it has been removed) is formed to the shape of tool 110 to provide the compacted stack 450 of Figure 4B, the vacuum and vacuum membrane 142 are removed, leaving behind the compacted stack 450 in tool 110, as shown in Figure 3M. Thus, the compacted stack 450 shown in Figure 3M and in Figure 4B is formed according to the shape of tool 110. When the second top support layer 221 is removed from the compacted pile 450, the result is a ceramic matrix composite structure 500, as shown in Figure 5. The ceramic matrix composite structure 500 comprises the second ceramic matrix composite layer 222 and the first ceramic matrix composite layer 212. The first fiber reinforcements 214 (Figure 2A) of the first ceramic matrix composite layer 212 and the second fiber reinforcements 224 (Figure 2B) of the second ceramic matrix composite layer 222 are oriented relative to each other during the placement of the first and second ceramic matrix composite layers 212, 222 onto the table 102 at the first location, such that the first and second fiber reinforcements 214, 224 reinforce each other. In the ceramic matrix composite structure 500, the first layer of ceramic matrix composite 212 has optional flanges 215, and the second layer of ceramic matrix composite 222 has optional flanges 225. The optional flanges 215, 225 depend on the shape of the tool surface 112 of tool 110, and on whether the optional steps 114 (Figure 1) are provided in the vicinity of the perimeter of tool 110. The optional flanges 215, 225 provide a fixing interface for the installation of the ceramic matrix composite structure 500. By way of example, an aircraft component or part of an aircraft may comprise the ceramic matrix composite material structure 500, including optional flanges 215 and 225. Aviation includes, for example, missiles, launch vehicles, high-speed aircraft, and rockets. Aircraft components include, for example, engine exhaust structures. Other types of aircraft and other aircraft components or systems are possible. Although the example of a ceramic matrix composite material structure 500 described above contains two layers (i.e., the first layer of ceramic matrix composite material 212 and the second layer of ceramic matrix composite material 222), it is conceivable that a ceramic matrix composite material structure may contain three or more layers. It is also conceivable that a ceramic matrix composite material structure may contain only one layer. Furthermore, although the preceding description states that the first bottom support film 213 is removed before the pile 400 in Figure 4A is compacted into the shape of tool 110, it is conceivable that the first bottom support film 213 is removed after the pile 400 has been compacted. For example, the compacted pile 450 in Figure 4B plus the first bottom support film 213 (assuming the first bottom support film 213 has not been previously removed) may need to be moved to a curing tool at another location to allow the compacted pile 450 to cure. In this case, the first bottom support film 213 can be removed once the compacted pile 450 has formed. With reference to Figure 6, a general flow diagram 600 represents an example method for manufacturing a ceramic matrix composite structure according to one embodiment. In block 602, a layer of ceramic matrix composite is collected at a first location before proceeding to block 604. In block 604, it is determined whether the layer of ceramic matrix composite collected in block 602 is the first layer collected. If the determination in block 604 is affirmative (i.e., it is the first layer collected), the process proceeds to block 606, in which the first layer collected is placed and lightly compacted on a table at the first location before the process proceeds to block 614. However, if the determination at block 604 is negative (i.e., it is not the first layer collected), the process proceeds to block 607 to detach an upper support film from the last layer placed on the table in the first location. The process then moves to block 608, where the lower support film is removed from the layer collected from block 602. Subsequently, at block 610, the sheet collected at block 602 is placed on top of the last sheet placed on the table. The process then proceeds to block 614. In block 614, it is subsequently determined whether another layer of ceramic matrix composite material should be added to fabricate the ceramic matrix composite structure. If the determination in block 614 is affirmative (i.e., another layer of ceramic matrix composite material should be added), the process returns to block 602 to process the next layer of ceramic matrix composite material. However, if the determination in block 614 is negative (i.e., no additional layer of ceramic matrix composite material is required), the process proceeds to block 616, where a stack of one or more layers of ceramic matrix composite material is provided. The process then proceeds to block 618. In block 618, the stack of one or more layers from block 616 is transported (i.e., moved) from the first location where the table is located to a second location where a tool is located. After removing the bottom support film from the stack, as shown in block 619, the stack of one or more layers is placed on the tool at the second location, as shown in block 620. A vacuum membrane is placed on the tool in block 622, and a vacuum is then applied, as shown in block 624, to compact the stack of ceramic matrix composite layers onto the tool. The process then moves to block 626, where the vacuum is released before any remaining support film, including the top support film of the last layer placed, is stripped from the compacted stack, as shown in block 628. The process then moves to block 630, where an in-situ inspection is performed to verify that the compacted stack has been placed, compacted, and removed correctly. After the inspection, the process moves to block 632, where the ceramic matrix composite structure is provided. The ceramic matrix composite structure contains at least one layer of ceramic matrix composite plus any ceramic matrix composite layers added in block 614.The process ends later. With reference to Figure 7, a flow diagram 700 represents an example of an electronically controlled method for fabricating a non-polymeric structure with a desired shape according to an embodiment. In block 702, a stack of at least first and second layers of non-polymeric material is conveyed from a surface at a first location to a tool surface at a second location, which is different from the first location, to enable the stack of at least first and second layers of non-polymeric material to be fabricated as the non-polymeric structure with the desired shape at the second location. The process is then terminated. With reference to Figure 8, a flow diagram 800 represents an example of an electronically controlled method for producing a ceramic matrix composite structure of a desired shape according to another embodiment. In block 802, a plurality of ceramic matrix composite layers are processed at a first location to form a stack of the plurality of ceramic matrix composite layers. The process then proceeds to block 804, where the stack of the plurality of ceramic matrix composite layers is transported from the first location to a second location located away from the first. Subsequently, in block 806, the stack of the plurality of ceramic matrix composite layers is processed at the second location to produce the ceramic matrix composite structure of the desired shape. The process then terminates. With reference to Figure 9, a flow diagram 900 represents an example of an electronically controlled method for fabricating a ceramic matrix composite structure with a desired shape according to another embodiment. In block 902, a first layer of ceramic matrix composite material is assembled, sandwiched between a first lower support layer and a first upper support layer. Subsequently, in block 904, the first layer of ceramic matrix composite material is placed on a table surface at a first location. The process then proceeds to block 906, where the first upper support film is peeled off the upper surface of the first layer of ceramic matrix composite material. The process then proceeds to block 908. In block 908, a second layer composed of ceramic matrix is collected, sandwiched between a second lower support layer and a second upper support layer. Subsequently, in block 910, the second lower support film is detached from a lower surface of the second ceramic matrix composite layer before being transferred to block 912. In block 912, the lower surface of the second ceramic matrix composite layer is placed on the upper surface of the first ceramic matrix composite layer to form a stack of at least the first and second ceramic matrix composite layers. Subsequently, in block 914, the stack of at least the first and second ceramic matrix composite layers is transported from the table surface at the first location to a tool surface at a second location that is different from the first location to allow the stack of at least the first and second ceramic matrix composite layers to be fabricated as the desired ceramic matrix composite structure at the second location. Several advantages result from providing the ceramic matrix composite structures described above (e.g., the 500 ceramic matrix composite structure shown in Figure 5) and their manufacturing methods. One advantage is that layering ceramic matrix composite materials into a tool is a fully automated process. Layer placement and compaction are automated, and on-site inspection of quality measures is provided. Quality measures that can be inspected on-site include, but are not limited to, layer location, fiber orientation, uncompacted regions, rework routing, and large defects of various types and sizes. Another advantage is the improvement in both the quality of the first pass and the consistency of the final product, as the placement and compaction of the ceramic matrix composite layers in a tool is automated. This results in fewer reworks, less labor, shorter cycle times, and therefore lower overall manufacturing costs. Another advantage is that the weight of a structure made from a ceramic-based material (for example, the ceramic matrix composite structure 500 in Figure 5) is less than that of the same structure made from a non-ceramic material, such as metal. Furthermore, the ability of the ceramic-based material to withstand high temperatures during the structure's operation is much greater than that of non-ceramic materials. A ceramic-based material can withstand temperatures up to 1315.55 degrees Celsius [2400 degrees Fahrenheit].The high-temperature capability of the ceramic-based material allows a structure fabricated from this material, such as an aircraft heat shield or an aircraft exhaust structure, to be exposed to consistently high temperatures (e.g., 815.56 degrees Celsius [1500 degrees Fahrenheit], which is beyond the limiting factor for most metals) during operational use. Thus, ceramic matrix composite structures fabricated according to this disclosure not only offer desirable weight advantages but also possess desirable thermal characteristics in applications where both weight and thermal characteristics are considered important. Examples of disclosure can be described in the context of an aircraft manufacturing and servicing method 1100, as shown in Figure 10, and an aircraft 1102, as shown in Figure 11. During preproduction, the aircraft manufacturing and servicing method 1100 may include the specification and design 1104 of the aircraft 1102 and the procurement of materials 1106. During production, the fabrication of components / subassemblies 1108 and the integration of systems 1110 of the aircraft 1102 take place. Thereafter, the aircraft 1102 may undergo certification and delivery 1112 for commissioning 1114. While in service with a customer, the aircraft 1102 is scheduled for routine maintenance and servicing 1116, which may also include modification, reconfiguration, refurbishment, and the like. Each of the processes in Method 1100 can be performed or carried out by a systems integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a systems integrator may include, but is not limited to, any number of aircraft manufacturers and major systems subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, etc. As shown in Figure 11, the aircraft 1102 produced by the example method 1100 may include a fuselage 1118 with a plurality of systems 1120 and an interior 1122. Examples of the plurality of systems 1120 may include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may be included. The disclosed apparatus and method may be employed during any stage of aircraft manufacturing and servicing method 1100. By way of example, the components or subassemblies corresponding to component / subassembly fabrication 1108, systems integration 1110, and / or maintenance and servicing 1116 may be assembled using the disclosed apparatus method. As another example, the fuselage 1118 may be constructed using the disclosed apparatus and method. Likewise, one or more examples of apparatus, examples of methods, or a combination thereof may be used during component / subassembly fabrication 1108 and / or systems integration 1110, for example, by substantially speeding up assembly or reducing the cost of an aircraft 1102, such as the fuselage 1118 and / or the interior 1122.Similarly, one or more of the system examples, method examples, or a combination thereof may be used while aircraft 1102 is in service, for example, and without limitation, to maintenance and service 1116. The aspects of the disclosed embodiments can be implemented in software, hardware, firmware, or a combination thereof. The various elements of the system, either individually or in combination, can be implemented as a computer program product (instruction program) tangibly embedded in a machine-readable storage device (storage medium) for execution by a processor. Several steps of the embodiments can be carried out by a computer processor executing a program tangibly embedded in a computer-readable medium to perform functions by operating on input and generating output. The computer-readable medium can be, for example, memory, a portable medium such as a compact disc or a flash drive, so that a computer program incorporating aspects of the disclosed embodiments can be loaded into a computer. An example of an electronically controlled method for fabricating a ceramic matrix composite material structure of a desired shape according to the present disclosure (see, for example, Figures 7, 8, 9) comprises the steps of processing (802) at a first location a plurality of ceramic matrix composite material layers to form a stack of the plurality of ceramic matrix composite material layers, transporting (804) the stack of the plurality of ceramic matrix composite material layers from the first location to a second location that is a distance from the first location,and processing (806) at the second location the stack of the plurality of ceramic matrix composite layers to provide the ceramic matrix composite structure with the desired shape. Placing a vacuum membrane at the second location against the stack of the plurality of ceramic matrix composite layers to provide a vacuum-tight seal against the stack. This may involve applying a vacuum to pull the vacuum membrane against the stack of the plurality of ceramic matrix composite layers and thereby shape the stack at the second location. It may also involve releasing the vacuum and, once the vacuum is released, providing the ceramic matrix composite structure with the desired shape. Preferably,Each layer of the stack of plurality layers of ceramic matrix composite material comprises a matrix and fiber reinforcements within the matrix. The matrix may include a ceramic base material, and the fiber reinforcements within the matrix may include ceramic fibers. Each layer of the stack of plurality layers of ceramic matrix composite material may be provided with a layer of ceramic matrix composite material with a fabric pre-impregnated with a matrix material. Optionally, the method may include orienting the fiber reinforcements of each layer of the stack of plurality layers of ceramic matrix composite material such that the fiber reinforcements reinforce each other when the ceramic matrix composite structure is fabricated into the desired shape. It may also consist of (see, for example,Figure 9) pick up (902) a first layer of ceramic matrix composite material sandwiched between a first lower support layer and a first upper support layer, place (904) the first layer of ceramic matrix composite material on a table surface at a first location, peel off (906) the first upper support layer from an upper surface of the first ceramic matrix composite layer, pick up (908) a second ceramic matrix composite layer sandwiched between a second lower support layer and a second upper support layer, peel off (910) the second lower support layer from a lower surface of the second ceramic matrix composite layer,The placement (912) of the lower surface of the second ceramic matrix composite layer onto the upper surface of the first ceramic matrix composite layer to form a stack comprising at least the first ceramic matrix composite layer and the second ceramic matrix composite layer, and the transport (914) of the stack from the table surface at the first location to a tool surface at a second location that is different from the first location to allow the stack to be fabricated as the ceramic matrix composite structure with the desired shape at the second location. Preferably, it includes, prior to transporting the stack from the table surface at the first location to the tool surface at the second location,Detaching the first lower support film from the underside of the first layer of ceramic matrix composite material and / or including, after transporting the stack from the table surface at the first location to the tool surface at the second location, shaping the stack to the shape of the tool surface, and subsequently detaching the first lower support film from the underside of the first layer of ceramic matrix composite material. Additionally, it may also involve placing a vacuum membrane against the stack to provide a vacuum-tight seal against the stack. This may further involve applying a vacuum to pull the vacuum membrane against the stack and thereby shape the stack to the shape of the tool surface at the second location and may also optionally involve releasing the vacuum, and after the vacuum is released,providing the ceramic matrix composite material structure with multiple layers of ceramic matrix composite material in the desired shape. Optionally, (i) the collection of a first layer of ceramic matrix composite material sandwiched between a first lower support layer and a first upper support layer includes the collection of a first layer of ceramic matrix composite material with a first matrix and fiber reinforcements within the first matrix, and (ii) the collection of a second layer of ceramic matrix composite material sandwiched between a second lower support layer and a second upper support layer includes the collection of a second layer of ceramic matrix composite material with a second matrix and fiber reinforcements within the second matrix. Optionally, each of the first and second matrices contains a ceramic base material,and the fiber reinforcements within the first and second matrices contain ceramic fibers. Optionally, (i) the collection of a first layer composed of a ceramic matrix sandwiched between a first lower support layer and a first upper support layer includes the collection of a first layer composed of a ceramic matrix with a first fabric pre-impregnated with a matrix material,and (ii) the collection of a second ceramic matrix composite layer sandwiched between a second lower support layer and a second upper support layer includes the collection of a second ceramic matrix composite layer with a second fabric pre-impregnated with a matrix material. The example may also include the orientation of the fiber reinforcements of each of the first ceramic matrix composite layer and the second ceramic matrix composite layer during the placement of the first ceramic matrix composite layer and the second ceramic matrix composite layer on the table surface in the first location such that the fiber reinforcements reinforce each other when the ceramic matrix composite structure is fabricated into the desired shape. Clearly, the example mentioned can be used advantageously in the manufacture of an aircraft part or component with multiple flanges. It can also be used advantageously in the manufacture of an aeronautical heat shield component. In another example (see Figures 7, 8, and 9), the layers may contain at least a first non-polymeric layer and a second non-polymeric layer to fabricate a non-polymeric structure. This includes transporting (702) a stack comprising at least a first non-polymeric layer and a second non-polymeric layer from a table surface at a first location to a tool surface at a second location, which is different from the first location, to enable the stack of at least the first non-polymeric layer and the second non-polymeric layer to be fabricated as the non-polymeric structure with the desired shape at the second location.Transporting the stack of at least the first non-polymeric layer and the second non-polymeric layer from the table surface at the first location to the tool surface at the second location may include transporting the stack of at least the first non-polymeric layer and the second non-polymeric layer from the table surface at the first location to the tool surface at the second location, wherein the first non-polymeric layer and the second non-polymeric layer comprise a ceramic matrix composite. Optionally or alternatively, it may include transporting the stack of at least the first non-polymeric layer and the second non-polymeric layer from the table surface at the first location to the tool surface at the second location.Furthermore, the transport of the stack of at least the first non-polymeric layer and the second non-polymeric layer from the table surface at the first location to the tool surface at the second location may include the transport of a stack of at least the first and second layers composed of a ceramic matrix with fiber reinforcements from the table surface at the first location to the tool surface at the second location. Optionally or alternatively, the transport may consist of transporting a stack of at least the first non-polymeric layer and the second non-polymeric layer with a fabric pre-impregnated with a matrix material from the table surface at the first location to the tool surface at the second location.Preferably, after transporting the stack from the first location to the second location, the following steps can be taken: lowering the stack onto the tool surface at the second location and / or applying a vacuum to at least the first and second non-polymeric layers of the stack to form a shaped stack that conforms to the tool surface, thereby providing the non-polymeric structure with the desired shape. Optionally, when applying a vacuum to the stack of at least the first and second layers of non-polymeric material, the process is further enhanced by encapsulating the stack using a vacuum membrane. Before applying the vacuum, a vacuum membrane can be placed on the stack to provide a vacuum-tight seal against the first and second non-polymeric layers.After applying the vacuum, it can be advantageous to peel off a support film from the stack formed from at least the first and second non-polymeric layers, and preferably from each of the first and second non-polymeric layers and the non-polymeric structure, to verify the placement and compaction of the first and second non-polymeric layers, and then remove the support film. It is advantageous if the weight of the non-polymeric structure for a given volume is less than the weight of an equivalent volume of a metallic structure. As in the previous example, the method described above can also be advantageously used to manufacture an aircraft part and / or an aircraft component having several flanges. Furthermore, it can be advantageously used to manufacture an aircraft heat shield component. The apparatus and method described above are described in the context of an aircraft. However, a person skilled in the art will readily recognize that the disclosed apparatus and method are suitable for a variety of applications, and this disclosure is not limited to aircraft manufacturing applications. For example, the disclosed apparatus and method can be applied to various types of vehicles, including, for example, helicopters, passenger ships, automobiles, marine products (boats, engines, etc.), and the like. Non-vehicle applications are also contemplated. Furthermore, although the preceding description outlines an apparatus and method for manufacturing a ceramic matrix composite structure for an aircraft component in the aerospace industry in accordance with military and aerospace regulations, it is envisaged that the apparatus and method can be implemented to facilitate the manufacture of a ceramic matrix composite structure in any industry in accordance with applicable industry standards. The specific apparatus and method can be selected and adapted based on the particular application. Furthermore, although several aspects of the disclosed embodiments have been shown and described, those skilled in the art may find modifications upon reading the specification. This application incorporates such modifications and is limited only by the scope of the claims.
Claims
1. An electronically controlled method (700, 800, 900) for manufacturing a ceramic matrix composite material structure (500) of a desired shape, the electronically controlled method comprising: - processing (block 802) at a first location a plurality of ceramic matrix composite material layers to form a stack (400) of the plurality of ceramic matrix composite material layers (212, 222), wherein the process comprises: - collecting (902) a first ceramic matrix composite material layer (212) sandwiched between a first lower support layer (213) and a first upper support layer (211); - placing (904) the first ceramic matrix composite material layer (212) onto the surface of a table (104) at a first location; - peeling (906) the first upper support film (211) from an upper surface of the first ceramic matrix composite material layer (212); - collect (908) a second layer of materialceramic matrix composite (222) sandwiched between a second lower support layer (223) and a second upper support layer (221); - peeling (910) the second lower support film (223) from a lower surface of the second ceramic matrix composite layer (222); - placing (912) the lower surface of the second ceramic matrix composite layer (222) onto the upper surface of the first ceramic matrix composite layer (212) to form a stack (400) comprising at least the first ceramic matrix composite layer (212) and the second ceramic matrix composite layer (222); - transporting (block 804) the stack (400) of several layers of ceramic matrix composite (212, 222) from a first location to a second location away from the first, wherein the transport comprises: - transporting (914) the stack (400) from the table surface (104) at the first location toa tool surface (112) at a second location that is different from the first location to allow the stack (400) to be fabricated as the ceramic matrix composite structure (500) with the desired shape at the second location; and - process (block 804) at the second location the stack (400) of plurality layers of ceramic matrix composite material (212, 222) to provide the ceramic matrix composite material structure (500) with the desired shape.
2. The electronically controlled method (700, 800, 900) according to claim 1, further comprising placing a vacuum membrane (142) at the second location against the stack (400) of the plurality of ceramic matrix composite material layers (212, 222) to provide a vacuum-tight seal against the stack (400), and further comprising optionally extracting a vacuum to pull the vacuum membrane (142) against the stack (400) of the plurality of composite material layersceramic matrix (212, 222) and thereby shaping the stack (400) at the second location, and further comprising optionally: - releasing the vacuum; and - after releasing the vacuum, providing the ceramic matrix composite structure (500) with the desired shape.
3. The electronically controlled method (700, 800, 900) according to any of the preceding claims, wherein each layer of the stack (400) of the plurality of ceramic matrix composite layers (212, 222) comprises a matrix and fiber reinforcements (214, 224) within the matrix, and preferably wherein the matrix comprises a ceramic base material, and the fiber reinforcements within the matrix comprise ceramic fibers; and / or wherein each layer of the stack (400) of the plurality of ceramic matrix composite layers (212, 222) comprises a ceramic matrix composite layer having a fabric pre-impregnated with a matrix material.
4. The controlled methodelectronically (700, 800, 900) according to any of the preceding claims, further comprising orienting the fiber reinforcements (214, 224) of each layer of the plurality of ceramic matrix composite material layers (212, 222) of the stack (400) such that the fiber reinforcements (214, 224) reinforce each other when the ceramic matrix composite material structure (500) is fabricated into the desired shape.
5. The electronically controlled method (700, 800, 900) according to any of the preceding claims, further comprising: - before transporting the stack (400) from the table surface (104) at the first location to the tool surface (112) at the second location, peeling the first lower support film (213) from a lower surface of the first ceramic matrix composite material layer (212); and / or - after transporting the stack (400) from the table surface (104) at the first locationup to the surface of the tool (112) at the second location, shaping the stack (400) to the shape of the tool surface (112), and subsequently peeling off the first lower support film (213) from a lower surface of the first ceramic matrix composite layer (212).
6. The electronically controlled method (700, 800, 900) according to any of the preceding claims, further comprising placing a vacuum membrane (142) against the stack (400) to provide a vacuum-tight seal against the stack (400), and optionally further comprising extracting a vacuum to pull the vacuum membrane (142) against the stack (400) and thereby shape the stack (400) to the shape of the tool surface (112) at the second location, and further optionally comprising: - releasing the vacuum; and - once the vacuum is released, provide the multi-layer ceramic matrix composite material structure (500)of ceramic matrix composite material (212, 222) of the desired shape.
7. The electronically controlled method (700, 800, 900) according to any of the preceding claims, wherein (i) the collection of a first ceramic matrix composite layer (212) sandwiched between a first lower support layer (213) and a first upper support layer (211) includes the collection of a first ceramic matrix composite layer (212) having a first matrix and fiber reinforcements (214) within the first matrix, and (ii) the collection of a second ceramic matrix composite layer (222) sandwiched between a second lower support layer (223) and a second upper support layer (221) includes the collection of a second ceramic matrix composite layer (222) having a second matrix and fiber reinforcements (224) within the second matrix, and optionally wherein each of the first matrix and the second matrix comprises a material ofceramic base, and the fiber reinforcements (214, 224) within the first matrix and the second matrix comprise ceramic fibers; and / or wherein (i) the taking of a first ceramic matrix composite layer (212) sandwiched between a first lower support layer (213) and a first upper support layer (211) includes the taking of a first ceramic matrix composite layer (212) having a first fabric that is pre-impregnated with a matrix material, (ii) the taking of a second ceramic matrix composite layer (222) sandwiched between a second lower support layer (223) and a second upper support layer (221) includes the taking of a second ceramic matrix composite layer (222) with a second fabric pre-impregnated with a matrix material.
8. The electronically controlled method (700, 800, 900) according to claim 7, further comprising orienting the fiber reinforcements (214, 224) of each of the first composite material layer ofceramic matrix (212) and the second ceramic matrix composite layer (222) during the placement of the first ceramic matrix composite layer (212) and the second ceramic matrix composite layer (222) on the table surface (104) in the first location such that the fiber reinforcements (214, 224) reinforce each other when the ceramic matrix composite structure (500) is manufactured in the desired shape.
9. The electronically controlled method (700, 800, 900) according to any of the preceding claims, wherein the stack (400) comprises at least a first non-polymeric layer (210) and a second non-polymeric layer (220), and wherein the transport comprises transporting (702) the stack (400) from a table surface (104) at a first location to a tool surface (112) at a second location, which is different from the first location, to allow the stack (400) to detach at least the first layernon-polymeric (210) and the second non-polymeric layer (220) is manufactured as the non-polymeric structure (500) with the desired shape at the second location; and optionally: - wherein transporting (702) the stack (400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) from the table surface (104) at the first location to the tool surface (112) at the second location comprises transporting the stack (400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) from the table surface (104) at the first location to the tool surface (112) at the second location, wherein the first non-polymeric layer (210) and the second non-polymeric layer (220) comprise a ceramic matrix composite; or - where transporting (702) the stack (400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) from the table surface (104) at the first locationto the tool surface (112) at the second location comprises transporting the stack (400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) from the table surface (104) at the first location to the tool surface (112) at the second location; or - wherein transporting the stack (400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) from the table surface (104) at the first location to the tool surface (112) at the second location includes transporting a stack (400) of at least the first and second ceramic matrix composite layers (212, 222) having fiber reinforcements (214, 224) from the table surface (104) at the first location to the tool surface (112) at the second location.
10. The electronically controlled method (700, 800, 900) according to claim 9: where the battery is transported(400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) from the table surface (104) at the first location to the tool surface (112) at the second location includes transporting a stack (400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) with a fabric pre-impregnated with a matrix material from the table surface (104) at the first location to the tool surface (112) at the second location; and / or further comprises, after transporting the stack (400) from the first location to the second location, lowering the stack (400) onto the tool surface (112) at the second location.
11. The electronically controlled method (700, 800, 900) according to claim 9 or 10, further comprising: applying a vacuum to the stack (400) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220) to form a stack (450)that conforms to a shape of the tool surface (112) and thereby provides the non-polymeric structure (500) with the desired shape.
12. The electronically controlled method (700, 800, 900) according to claim 11, wherein applying the vacuum to the stack (400) of at least first and second non-polymeric layers of material (210, 220) comprises bagging the stack (400) using a vacuum membrane (142); and / or further comprises, before applying the vacuum, placing a vacuum membrane (142) over the stack (400) to provide a vacuum-tight seal against the first non-polymeric layer (210) and the second non-polymeric layer (220); and / or further comprising, after applying the vacuum, removing a support film (213, 221) from the stack formed (450) of at least the first non-polymeric layer (210) and the second non-polymeric layer (220), and optionally further comprising inspecting each of the first non-polymeric layer (210) and the second non-polymeric layer (220).polymeric (220) and the non-polymeric structure (500) to verify the placement and compaction of the first non-polymeric layer (210) and the second non-polymeric layer (220), and to remove the backing film.
13. The electronically controlled method (700, 800, 900) according to any one of claims 9 to 12, wherein the weight of the non-polymeric structure (500) for a given volume of the non-polymeric structure (500) is less than the weight of an equivalent volume of a metallic structure.
14. A method for manufacturing an aircraft part (500) using the electronically controlled method according to any one of the preceding claims.
15. A method for manufacturing an aircraft part (500) using the electronically controlled method according to any one of claims 1 to 13, wherein: - the aircraft part (500) has a series of flanges (215, 225); or - the aircraft part (500) comprises a heat shield aircraft part (500).