Systems and methods for infiltrating porous ceramic matrix composite (CMC) preforms - Patents.com

Abstract

To provide a system and a method for penetrating a porous ceramic matrix composite material (CMC) preform.SOLUTION: A method comprises a process (P1) where a CMC preform is positioned at an opening part of a die set for an infiltration system; a process (P2) where a molten densification agent is caused to flow onto the CMC preform in a first flow direction; and a process where a plurality of voids formed between each of a plurality of ply stacks of the CMC preform. The method can contain a process (P3) where a molten densification agent is caused to flow in a second flow direction separate from the first flow direction, and a process where the void is infiltrated. The second flow direction may be substantially parallel to the prescribed one direction material orientation of at least one ply stack of the plurality of ply stacks.SELECTED DRAWING: Figure 10

Description

[Technical field]

[0001] The present disclosure relates generally to ceramic matrix composite (CMC) articles, and more particularly to systems and methods for infiltrating a porous CMC preform to form a CMC article. [Background technology]

[0002] Ceramic matrix composite (CMC) articles are generally considered well suited for structural components in turbine engines due to, for example, their heat resistance, high temperature strength, and chemical stability. However, turbine engine CMC articles can be subject to damage due to excessive stress, excessive temperature, improper formation, and the like. One technique to address the damage-prone nature of CMC articles is densification. However, conventional systems and methods for performing densification can create, for example, obstructions, cracks, and / or areas of reduced material, causing weaknesses within the CMC article. These shortcomings associated with conventional densified CMC articles tend to be exacerbated as the CMC article becomes thicker.

[0003] Conventional techniques for casting parts (e.g., metal casting) include injection molding, high pressure die casting, and low pressure die casting. However, these conventional techniques for casting have not been utilized to perform densification processes on CMC articles because the operating parameters for performing the techniques may increase the likelihood of and / or cause damage to the CMC article when performing the densification process. Summary of the Invention

[0004] A first aspect of the present disclosure provides a method for infiltrating a porous ceramic matrix composite (CMC) preform, the method including: positioning a porous CMC preform in an opening of a die set for an infiltration system, the CMC preform including a plurality of ply stacks, each of the plurality of ply stacks including a predetermined unidirectional material orientation and a plurality of voids formed between each of the plurality of ply stacks, flowing a molten densifying agent onto the porous CMC preform in a first flow direction to infiltrate the plurality of voids formed between each of the plurality of ply stacks of the CMC preform, and flowing a molten densifying agent onto the porous CMC preform in a second flow direction distinct from the first flow direction to infiltrate the plurality of voids formed between each of the plurality of ply stacks of the CMC preform, the second flow direction being substantially parallel to the predetermined unidirectional material orientation of at least one ply stack of the plurality of ply stacks of the CMC preform.

[0005] A second aspect of the present disclosure provides a system including a die set including an opening for receiving a porous ceramic matrix composite (CMC) preform; a first molten densifier supply conduit in communication with the opening at a first location of the die set, the first molten densifier supply conduit flowing molten densifier to the opening of the die set in a first flow direction to infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform; and a second molten densifier supply conduit in communication with the opening of the die set at a second location of the die set, the second molten densifier supply conduit flowing molten densifier to the opening of the die set in a second flow direction substantially parallel to a predetermined unidirectional material orientation of at least one of the plurality of ply stacks of the CMC preform to infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform.

[0006] The illustrative aspects of the present disclosure are designed to solve the problems described herein and / or other problems not discussed.

[0007] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure, taken in conjunction with the accompanying drawings which illustrate various embodiments of the present disclosure. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic diagram of a system for infiltrating a porous ceramic matrix composite (CMC) preform to form a CMC article, according to an embodiment of the present disclosure. [Diagram 2] 2 is a cross-sectional front view of the system and CMC preform taken along line 2-2 of FIG. 1 according to an embodiment of the disclosure. [Diagram 3] FIG. 3 is an enlarged view of a portion of FIG. 2 including a system and a CMC preform according to an embodiment of the present disclosure. [Figure 4] FIG. 13 is a cross-sectional front view of a system and a CMC preform according to an additional embodiment of the present disclosure. [Diagram 5] FIG. 2 is another schematic diagram of a system for infiltrating a porous ceramic matrix composite (CMC) preform to form a CMC article according to a further embodiment of the present disclosure. [Figure 6] 6 is an enlarged view of a portion of FIG. 5 including a system and a CMC preform according to an embodiment of the present disclosure. [Figure 7] 6 is an enlarged view of a portion of FIG. 5 including a system and a CMC preform according to an additional embodiment of the present disclosure. [Figure 8] 6 is an enlarged view of a portion of FIG. 5 including a system and a CMC preform according to another embodiment of the present disclosure. [Figure 9] FIG. 2 is another schematic diagram of a system for infiltrating a porous ceramic matrix composite (CMC) preform to form a CMC article according to a further embodiment of the present disclosure. [Figure 10] 1 is an illustrative flow diagram of an example process for infiltrating a porous ceramic matrix composite (CMC) preform to form a CMC article, according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] It should be noted that the drawings of the present disclosure are not drawn to scale. The drawings are intended to illustrate only typical aspects of the present disclosure and therefore should not be considered as limiting the scope of the present disclosure. In the drawings, like numbers represent like elements between the drawings.

[0010] As a first issue, in order to clearly explain the present disclosure, it becomes necessary to select specific terminology when referring to and describing the relevant machine components in this disclosure. When doing so, common industry terminology is used and utilized, whenever possible, with the same meaning as its accepted meaning. Unless otherwise noted, such terminology should be given a broad interpretation consistent with the context of this application and the scope of the appended claims. Those skilled in the art will appreciate that in many cases, a particular component may be referred to using several different or overlapping terms. What may be described herein as being a single part may include and be referred to in other contexts as being made up of multiple components. Alternatively, what may be described herein as comprising multiple components may be referred to elsewhere as a single part.

[0011] As noted above, the present disclosure relates generally to ceramic matrix composite (CMC) articles, and more particularly, to systems and methods for infiltrating a porous CMC preform to form a CMC article.

[0012] These and other embodiments are described below with reference to Figures 1-10. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for illustrative purposes only and should not be construed as limiting.

[0013] 1 and 2 show various views of a system 100 capable of infiltrating a porous ceramic matrix composite (CMC) preform 102 (hereinafter "CMC preform 102") contained therein. More specifically, FIG. 1 shows a schematic diagram of the system 100 and the CMC preform 102 (shown in phantom), and FIG. 2 shows a front cross-sectional view of the system 100 and the CMC preform 102 taken along line 2-2 of FIG. 1. As described herein, the system 100 can be configured to flow a molten densifying agent onto the CMC preform 102 to infiltrate and / or densify the preform 102 to create a CMC article (not shown) that can be utilized in various systems and / or devices (e.g., hot gas path components of a turbine system).

[0014] The system 100 may include a die set 104 configured to receive the preform 102 for infiltration, as described herein. In a non-limiting example, the die set 104 may include a first portion 106 and a second portion 108 positioned and / or coupled to the first portion 106. The die set 104 may also include an opening 110 formed therein. Specifically, the opening 110 may be formed in the first portion 106 and / or between the first portion 106 and the second portion 108 of the die set 104. As shown in FIGS. 1 and 2, the opening 110 is capable of receiving, containing, and / or holding the CMC preform 102 during the infiltration process performed using the system 100. The die set 104 may be formed from any suitable material capable of receiving the CMC preform 102 and capable of withstanding pressures and / or material exposure temperatures (e.g., molten densifying agent) experienced when performing an infiltration process on the CMC preform 102, as described herein. Additionally, although the openings 110 in the die set 104 are shown as substantially polygonal / quadrilateral, it is understood that the openings 110 may be formed as and / or include any configuration for receiving the CMC preform 102 and performing the infiltration process.

[0015] As shown in Figures 1 and 2, the system 100 may also include at least one molten densification agent source 112. The molten densification agent source 112 of the system 100 may hold, contain, and / or store a molten densification agent 118 (Figure 2) that may be supplied, flowed, and / or infiltrated into the CMC preform 102 during the infiltration process as described herein. The molten densification agent 118 may include any suitable molten source of a compound or composition capable of infiltrating and / or increasing the density of the CMC preform 102 to form a CMC article (not shown). For example, the molten densification agent 118 may include one or more molten sources of silicon. Although a single molten densification agent source 112 is shown in Figures 1 and 2, it is understood that the system 100 may include more sources for providing the molten densification agent 118 to the opening 110 of the die set 104 during the infiltration process (Figure 9).

[0016] The molten densifying agent source 112 can be in communication with the die set 104 via a number of supply conduits. For example, the molten densifying agent source 112 can be in communication with a first molten densifying agent supply conduit 120 (hereinafter, "first supply conduit 120"). The first supply conduit 120 can also be in communication with and / or couple the molten densifying agent source 112 to the opening 110 of the die set 104. As described herein, the first supply conduit 120 can provide, supply, and / or flow the molten densifying agent 118 (FIG. 2) to the opening 110 in a first flow direction D1 (FIG. 2) during an infiltration process to infiltrate a number of voids in the CMC preform 102 formed between each of a number of ply stacks (FIG. 3) forming the CMC preform 102. The first supply conduit 120 can be in communication with the die set 104 at a first location 122 of the die set 104. In the non-limiting example shown in FIGS. 1 and 2, the first location 122 of the first supply conduit 120 can be in and / or through the second portion 108 of the die set 104. In addition, the first location 122 of the first supply conduit 120 can also be substantially above the opening 110 of the die set 104 and / or the CMC preform 102 positioned within the opening 110. Thus, as described herein, the first supply conduit 120 positioned at the first location 122 of the die set 104 in the system 100 can provide, supply, and / or flow the molten densifying agent 118 onto the upper or top surface of the CMC preform 102 to infiltrate voids within the CMC preform 102 from top to bottom.

[0017] 2, the first supply conduit 120 may also include an inlet 124 in direct communication with the opening 110 of the die set 104. In a non-limiting example in which the first supply conduit 120 is positioned at a first location 122 (e.g., above the CMC preform 102), the first supply conduit 120 may flow and / or supply the molten densifying agent 118 to the opening 110 and / or the CMC preform 102 in a first flow direction (D1) at a pressure equal to (or less than) atmospheric pressure. That is, as shown in FIGS. 1 and 2, the molten densifying agent source 112 and the first supply conduit 120 may be configured as a gravity feed system that may flow the molten densifying agent 118 at a pressure equal to (or less than) atmospheric pressure. In another non-limiting example described herein (FIG. 4), the first supply conduit 120 can flow and / or supply the molten densifying agent 118 in a first flow direction (D1) at a pressure above atmospheric pressure.

[0018] 1 and 2, the molten densifying agent source 112 may be in communication with a second molten densifying agent supply conduit 126 (hereinafter, "second supply conduit 126"). Similar to the first supply conduit 120, the second supply conduit 126 may be in communication with and / or couple the molten densifying agent source 112 to the opening 110 of the die set 104. As described herein, the second supply conduit 126 may provide, supply, and / or flow the molten densifying agent 118 (FIG. 2) to the opening 110 in a second flow direction D2 (FIG. 2) during an infiltration process to infiltrate a plurality of voids in the CMC preform 102 formed between each of a plurality of ply stacks (FIG. 3) forming the CMC preform 102. In a non-limiting example, the second supply conduit 126 may be in communication with the die set 104 at a second location 128 of the die set 104 that is separate from the first location 122 of the first supply conduit 120. As shown in FIGS. 1 and 2 , the second location 128 of the second supply conduit 126 may be in and / or through a sidewall 130 of the first portion 106 of the die set 104. In addition, the second location 128 of the second supply conduit 126 may also be positioned substantially adjacent to, next to, and / or horizontally away from the opening 110 of the die set 104 and / or a CMC preform 102 positioned within the opening 110. Thus, as described herein, a second supply conduit 126 positioned at a second location 128 of the die set 104 in the system 100 can provide, supply, and / or flow molten densification agent 118 through the side of the CMC preform 102 to infiltrate voids within the CMC preform 102 from the side.

[0019] 2, and similar to the first supply conduit 120, the second supply conduit 126 may also include an inlet 132 in direct communication with the opening 110 of the die set 104. In a non-limiting example in which the second supply conduit 126 is positioned at the second location 128 (e.g., adjacent to the CMC preform 102) and the molten densifying agent source 112 is positioned above or rises from the second location 128, the second supply conduit 126 may flow and / or supply the molten densifying agent 118 in a second flow direction (D2) at a pressure equal to (or less than) atmospheric pressure to the opening 110 and / or the CMC preform 102 (e.g., a gravity feed system). In other non-limiting examples described herein (FIG. 4), the second supply conduit 126 may flow and / or supply the molten densifying agent 118 in a second flow direction (D2) at a pressure equal to (or less than) atmospheric pressure.

[0020] With reference to FIG. 3 and with continuing reference to FIGS. 1 and 2, an expanded view of a portion of the CMC preform 102 and system 100 of FIG. 2 is shown. In a non-limiting example, the CMC preform 102 can include multiple ply stacks 134, 136 of material. Each ply stack 134, 136 of the CMC preform 102 can include multiple processed fibers formed into a single sheet of material, sometimes referred to as a "tape." The fibers of each ply stack 134, 136 can include a predetermined unidirectional material orientation. For example, as shown in FIG. 3, the ply stack 134 can include fibers having a first predetermined unidirectional material orientation that extends across the page and / or from left to right when viewed in a front cross-sectional view (FIG. 2). Separate from the ply stack 134, the ply stack 136 can include fibers having a separate predetermined unidirectional material orientation that extends through and / or into and out of the page when viewed in a front cross-sectional view (FIG. 2). The CMC preform 102 may include multiple ply stacks 134, 136 stacked and / or positioned relative to one another to form a CMC article (not shown) after the infiltration process described herein. Additionally, the pattern and / or order in which the ply stacks 134, 136 are stacked, positioned relative to one another, and / or oriented to form the CMC preform 102 may depend on the build structure and / or CMC article to be formed from the CMC preform 102. For example, as shown in FIG. 3, the CMC preform 102 may include more ply stacks 134 than ply stacks 136 depending on the properties (e.g., stiffness, ductility, flexibility, etc.) of the ply stacks 134, 136 and the properties required for the CMC article to be formed from the CMC preform 102.

[0021] In addition, as shown in FIG. 3, the CMC preform 102 may also include a plurality of voids 138. The voids 138 in the CMC preform 102 may be formed between each ply stack 134, 136 as a result of the formation and / or stacking of the ply stacks 134, 136 to form the CMC preform 102. To form a CMC article from the CMC preform 102, the voids 138 formed in the CMC preform 102 must be substantially closed and / or filled. As described herein, the system 100 may perform a densification process on the CMC preform 102 by flowing or delivering a molten densifying agent 118 to the openings 110 of the die set 104 to flow through and / or between the ply stacks 134, 136 to substantially fill the voids 138 during the infiltration process.

[0022] 2 , as described herein, the first supply conduit 120 communicates with the opening 110 of the die set 104 at a first location 122 (e.g., the second portion 108 above the CMC preform 102) to flow the molten densifying agent 118 onto the CMC preform 102. In a non-limiting example, the first flow direction (D1) in which the first supply conduit 120 may flow, supply, and / or provide the molten densifying agent 118 is substantially up and down on the page, as the first location 122 is above and / or on the CMC preform 102 and / or opening 110 of the die set 104. 3 , a first flow direction (D1) of the molten densifying agent 118 provided, fed, and / or flowed onto the CMC preform 102 may be substantially perpendicular to the CMC preform 102, and more specifically, may be perpendicular to a predetermined unidirectional material orientation of at least one ply stack 134, 136 of the CMC preform 102. The first flow direction (D1) of the molten densifying agent 118 provided or flowed by the first supply conduit 120 may be substantially perpendicular to a predetermined unidirectional material orientation of at least one ply stack 134, 136 of the CMC preform 102, at least in part as a result of the first supply conduit 120 being positioned at the first location 122 of the die set 104 and / or the orientation and / or pattern of the multiple ply stacks 134, 136 forming the CMC preform 102.

[0023] As shown in FIG. 3 and described herein, the second supply conduit 126 can be formed in the die set 104 at a second location 128 (e.g., sidewall 130—FIG. 1) to supply or flow the molten densifying agent 118 to the opening 110 and / or flow the molten densifying agent 118 onto the CMC preform 102 in a second flow direction (D2). In a non-limiting example, the second flow direction (D2) can be substantially parallel to a predetermined unidirectional material orientation of at least one ply stack 134, 136 of the CMC preform 102. More specifically, the second flow direction (D2) of the molten densifying agent 118 flowed, supplied, and / or provided by the second supply conduit 126 can be substantially parallel to a predetermined unidirectional material orientation of the ply stack 134 of the CMC preform 102. By orienting the second supply conduit 126 (and / or inlet 132) to flow the molten densifying agent 118 in a second flow direction (D2) substantially parallel to the predetermined unidirectional material orientation of the ply stack 134 of the CMC preform 102, the molten densifying agent 118 may more efficiently and / or effectively flow, fill, and / or infiltrate through the voids 138 of the CMC preform 102. Flowing the molten densifying agent substantially parallel to the predetermined unidirectional material orientation of the ply stack 134 of the CMC preform 102 may improve the density of a CMC article formed from the CMC preform 102 and / or reduce / eliminate the size and / or number of under-infiltrated regions of the CMC preform 102 after performing an infiltration process using the system 100, as described herein. Using system 100 to increase the density of CMC preform 102 and / or reduce / eliminate the size and / or number of less permeated regions can reduce / eliminate the amount of potential defects in a CMC article formed from CMC preform 102 and / or increase the operating life and / or operating efficiency of the CMC article.

[0024] Although the second supply conduit 126 is described and shown herein as being formed in the die set 104 to supply or flow the molten densifying agent 118 in the second flow direction (D2), it is understood that the CMC preform 102 can be positioned or oriented in the opening 110 to align the ply stacks 134, 136 and the second supply conduit 126. That is, in addition to knowing that the second supply conduit 126 is formed in the second location 128 of the die set 104, the predetermined unidirectional material orientation of each ply stack 134, 136 can also be known. Thus, the CMC preform 102 can be positioned and / or oriented in the opening 110 of the die set 104 to substantially align the predetermined unidirectional material orientation of at least one ply stack 134, 136 of the CMC preform 102 with the second flow direction (D2) of the molten densifying agent 118 supplied by the second supply conduit 126. As described herein, aligning the predetermined unidirectional material orientation of the ply stacks 134, 136 with the second flow direction (D2) can improve the density of the CMC article formed from the CMC preform 102 and / or reduce / eliminate the size and / or number of less permeated regions of the CMC preform 102.

[0025] 4 illustrates another non-limiting example of the system 100. Specifically, FIG. 4 illustrates a front cross-sectional view of another non-limiting example of the system 100. It is understood that similarly numbered and / or named components may function in a substantially similar manner. Redundant descriptions of these components have been omitted for clarity.

[0026] As shown in FIG. 4 , the system 100 can also include a third molten densifying agent supply conduit 140 ("third supply conduit 140"). The third supply conduit 140 can be in communication with a molten densifying agent source 112 for receiving the molten densifying agent 118 contained therein. Additionally, similar to the first supply conduit 120 and the second supply conduit 126, the third supply conduit 140 can be in communication with the opening 110 of the die set 104 via an inlet 144 and / or can couple the molten densifying agent source 112 to the opening 110 of the die set 104. In a non-limiting example, the third supply conduit 140 can be in communication with the die set 104 at a third location 142 of the die set 104 that is separate from the first location 122 and the second location 128. 3, the third location 142 of the third supply conduit 140 may be in and / or through a sidewall 146 of the first portion 106 of the die set 104 opposite the sidewall 130. In addition, the third location 142 of the third supply conduit 140 may also be substantially adjacent to, next to, and / or horizontally away from the opening 110 of the die set 104 and / or the CMC preform 102 positioned within the opening 110.

[0027] As similarly described herein with respect to Figures 1-3, the third supply conduit 140 can provide, feed, and / or flow the molten densifying agent 118 to the opening 110 in a third flow direction (D3) to infiltrate the plurality of voids 138 of the CMC preform 102 formed between each ply stack 134, 136. In a non-limiting example shown in Figure 4, the third flow direction (D3) defined by the third supply conduit 140 can be separate from the first flow direction (D1) defined by the first supply conduit 120, but can be substantially similar or identical to the second flow direction (D2) defined by the second supply conduit 126. In another non-limiting example (Figures 5 and 6) described herein, the third flow direction (D3) defined by the third supply conduit 140 can be separate from the first flow direction (D1) and the second flow direction (D2). As similarly described herein with respect to the second supply conduit 126 of Figures 1-3, the third flow direction (D3) can be substantially parallel to a predetermined unidirectional material orientation of the ply stacks 134, 136 of the CMC preform 102. That is, if the CMC preform 102 shown in Figure 4 includes a configuration of ply stacks 134, 136 similar to that shown in Figure 3, the molten densifying agent 118 may flow and / or be supplied in a third flow direction (D3) that is substantially parallel to the predetermined unidirectional material orientation of the ply stacks 134 of the CMC preform 102. As a result, the third supply conduit 140 can supply the molten densifying agent 118 to flow through, fill, and / or infiltrate voids 138 of the CMC preform 102 to improve the density of a CMC article formed from the CMC preform 102 and / or reduce / eliminate the size and / or number of under-infiltrated regions of the CMC preform 102, as described herein.

[0028] Additionally, as shown in FIG. 4 , the system 100 may include a plunger 148 in communication with the molten densifying agent source 112. That is, the plunger 148 may connect to and / or interact with the molten densifying agent source 112 and apply a force to the molten densifying agent 118 contained in the molten densifying agent source 112. By applying the force, the plunger 148 may push and / or drive the molten densifying agent 118 through the first supply conduit 120, the second supply conduit 126, and the third supply conduit 140 to the opening 110 of the die set 104 and through the CMC preform 102, as described herein. The force applied by the plunger 148 may be substantially controlled and / or varied to control and / or adjust the pressure and / or rate of the molten densifying agent 118 flowing through the respective supply conduits 120, 126, 140. Thus, separate from the gravity feed system described in the non-limiting examples shown in Figures 1-3, the system 100 of Figure 4 can feed molten densification agent 118 onto the CMC preform 102 in a first flow direction (D1), a second flow direction (D2), and / or a third flow direction (D3) at pressures above atmospheric pressure.

[0029] 5 and 6 show additional non-limiting examples of the system 100. Specifically, FIG. 5 shows a front view of an additional non-limiting example of the system 100, and FIG. 6 shows an enlarged side cross-sectional view of a portion of FIG. 5 including the third supply conduit 140 of the system 100 and the CMC preform 102. It is understood that similarly numbered and / or named components may function in a substantially similar manner. Redundant descriptions of these components have been omitted for clarity.

[0030] As shown in FIG. 5, the third supply conduit 140 may be positioned at a location on the die set 104 that is separate from the locations described herein with respect to FIG. 4. For example, the third supply conduit 140 may be in communication with the die set 104 at a third location 142 of the die set 104 that is separate from the first location 122 and the second location 128 located in and / or through a sidewall 150 of the first portion 106 of the die set 104. The sidewall 150 may be formed and / or positioned between the opposing sidewalls 130, 146. As described herein, the third supply conduit 140 may be formed through the sidewall 150 and / or at the third location 142 of the die set 104 to flow and / or supply the molten densifying agent 118 in a third flow direction (D3) through the sidewall 150 and / or to the opening 110 to infiltrate the plurality of voids 138 of the CMC preform 102 formed between each ply stack 134, 136.

[0031] 5 may also include a separate molten densification agent source 152. In this example, the first supply conduit 120 may be in communication with the molten densification agent source 112, and the second supply conduit 126 and the third supply conduit 140 may be in communication with the separate molten densification agent source 152. In one non-limiting example, the separate molten densification agent source 152 may include a molten densification agent 118 similar to the molten densification agent source 112. Alternatively, the separate molten densification agent source 152 may include a molten densification agent that is separate from the molten densification agent 118 included in the molten densification agent source 112. In this non-limiting example, the separate molten densification agent contained in the separate molten densification agent source 152 may include a material, composition, and / or physical properties separate from the molten densification agent 118 to improve infiltration and / or densification of the CMC preform 102, as described herein.

[0032] With reference to FIG. 6 and with continuing reference to FIG. 5, an enlarged cross-sectional side view of a portion of the system 100 is shown. The CMC preform 102 shown in FIG. 6 may be identical to the CMC preform 102 shown and described herein with respect to FIG. 3. Thus, the CMC preform 102 of FIG. 6 may include a similar pattern and / or order in which the ply stacks 134, 136 are stacked, positioned relative to one another, and / or oriented. However, because FIG. 6 illustrates a side view rather than a front view as in FIG. 3, the predetermined unidirectional material orientation of each ply stack 134, 136 of the CMC preform may be opposite to that shown in FIG. 3. That is, as shown in FIG. 6, the ply stack 134, when viewed in a side cross-sectional view, may include fibers having a predetermined unidirectional material orientation extending through and / or into and out of the page, and the ply stack 136, when viewed in a side cross-sectional view, includes fibers having a predetermined unidirectional material orientation extending across and / or from left to right across the page.

[0033] 6 and described herein, a third supply conduit 140 can be formed in the die set 104 at a third location 142 (e.g., sidewall 146 - FIG. 4, sidewall 150 - FIG. 5) to supply or flow molten densifying agent 118 to the opening 110 and / or flow molten densifying agent 118 onto the CMC preform 102 in a third flow direction (D3). In a non-limiting example, the third flow direction (D3) defined by the third supply conduit 140 formed at the third location 142 and / or through the sidewalls 146, 150 can be separate from both the first flow direction (D1) defined by the first supply conduit 120 and the second flow direction (D2) defined by the second supply conduit 126. 6 , the third flow direction (D3) may be substantially parallel to a predetermined unidirectional material orientation of at least one ply stack 134, 136 of the CMC preform 102. More specifically, the third flow direction (D3) of the molten densifying agent 118 flowed, delivered, and / or provided by the third supply conduit 140 may be substantially parallel to the predetermined unidirectional material orientation of the ply stack 136 of the CMC preform 102.

[0034] By orienting the third supply conduit 140 (and / or inlet 144) to flow the molten densifying agent 118 in a third flow direction (D3) substantially parallel to the predetermined unidirectional material orientation of the ply stack 136 of the CMC preform 102, the molten densifying agent 118 may more efficiently and / or more effectively flow, fill, and / or infiltrate through the voids 138 of the CMC preform 102. Flowing the molten densifying agent substantially parallel to the predetermined unidirectional material orientation of the ply stack 136 of the CMC preform 102 may improve the density of a CMC article formed from the CMC preform 102 and / or reduce / eliminate the size and / or number of under-infiltrated regions of the CMC preform 102 after performing an infiltration process using the system 100, as described herein.

[0035] Additionally, in this non-limiting example, the second flow direction (D2) (not shown) of the molten densifying agent 118 flowed, fed, and / or provided by the second supply conduit 126 can be substantially parallel to a predetermined unidirectional material orientation of the ply stack 134 of the CMC preform 102, as also described herein with respect to FIG. 3. As a result, the second supply conduit 126 and the third supply conduit 140 of the system 100 can each flow the molten densifying agent 118 in a particular flow direction (D2, D3) that is parallel to either the ply stack 134 or the ply stack 136. The system 100 can further improve the efficiency and / or effectiveness with which the voids 138 formed between the ply stacks 134, 136 of the CMC preform 102 are filled, as shown in FIG. 6, ultimately improving the infiltration and / or densification of the CMC preform 102, as described herein.

[0036] At least one of the supply conduits 120, 126, 140 of the system 100 may also include a feature 154 formed on and / or adjacent to the inlet 124, 132, 144. The feature 154 of the supply conduits 120, 126, 140 may assist in controlling and / or regulating (e.g., increasing, decreasing) the pressure and / or rate at which the molten densifying agent 118 is supplied and / or flowed to the opening 110 of the die set 104 for the system 100. In a non-limiting example shown in FIG. 6, the feature 154 of the third supply conduit 140 may include an enlarged portion 156 of the third supply conduit 140 formed adjacent to and / or within the inlet 144. The enlarged portion 156 may include a varying diameter or geometry that may be larger than the diameter or geometry of the remainder of the third supply conduit 140. The inclusion of the expanding portion 156 in the third supply conduit 140 can control, and more specifically, reduce, the velocity of the molten densifying agent 118 before it enters the opening 110 and flows in the third flow direction (D3) onto the CMC preform 102. Additionally, the expanding portion 156 of the third supply conduit 140 can control, and more specifically, reduce, the pressure of the molten densifying agent 118 before it enters the opening 110. Controlling the pressure and / or velocity of the molten densifying agent 118 can control and / or improve the infiltration and / or densification of the CMC preform 102, as described herein.

[0037] In another non-limiting example, the feature 154 may include an adjustable valve 158. As shown in FIG. 7, the second supply conduit 126 may include an adjustable valve 158 formed adjacent the inlet 132. The adjustable valve 158 may vary the diameter or geometry of a portion of the second supply conduit 126 positioned adjacent the inlet 132. Similar to the enlarged portion 156 (FIG. 6), the adjustable valve 158 formed in the second supply conduit 126 may control or adjust (e.g., increase, decrease, maintain) the velocity and / or pressure of the molten densifying agent 118 before it enters the opening 110 and flows in the second flow direction (D2) onto the CMC preform 102. That is, by adjusting the diameter or geometry of the portion of the second supply conduit 126 positioned adjacent the opening 132, the adjustable valve 158 may control the pressure and / or velocity of the molten densifying agent 118. This in turn can improve the infiltration and / or densification of the CMC preform 102 as described herein.

[0038] Although shown and described herein as being included only in the second supply conduit 126 (FIG. 7) or the third supply conduit 140 (FIG. 6), it is understood that any supply conduit 120, 126, 140 of the system 100 may include features 154 for controlling the rate and / or pressure of the molten densifying agent 118. For example, the first supply conduit 120 of the system 100 may also include features 154 (enlarged portion 156, adjustable valve 158) formed within and / or adjacent to the inlet 124 to control the rate and / or pressure of the molten densifying agent 118 supplied or flowed to the opening 110 of the die set 104 in the first flow direction (D1). In addition, it is understood that any combination of the supply conduits 120, 126, 140 of the system may include features 154 for controlling the rate and / or pressure of the molten densifying agent 118. For example, both the first supply conduit 120 and the second supply conduit 126 may include features 154 formed therein.

[0039] FIG. 8 illustrates another non-limiting example of the second supply conduit 126 of the system 100. In a non-limiting example, the second supply conduit 126 may include a splitter or partition that divides the second supply conduit 126 into two separate sections 160, 162. The second supply conduit 126 may include two separate sections 160, 162 for providing the molten densifying agent 118 in two separate flow directions to infiltrate the CMC preform 102. That is, as shown in FIG. 8, a non-limiting example of the CMC preform 102 may include ply stacks 134, 136, 164, 166 that may be oriented and / or stacked in separate patterns relative to one another. For example, the portion of the CMC preform 102 illustrated in FIG. 8 may include ply stacks 134, 136 that are stacked, patterned, and / or oriented in a manner similar to that described herein with respect to FIG. 3. Additionally, the portion of the CMC preform 102 shown in Figure 8 may include ply stacks 164, 166, which may be positioned below the ply stacks 134, 136 and oriented, positioned, and / or stacked substantially perpendicular to the ply stacks 134, 136 based on the desired structure and / or configuration of the CMC preform 102. The ply stack 164 may include fibers having a first predetermined unidirectional material orientation that extends onto and / or from top to bottom of the page when viewed in cross section in Figure 6. The ply stack 166 may include fibers having a separate predetermined unidirectional material orientation that extends through and / or into and out of the page when viewed in cross section.

[0040] Each separate section 160, 162 of the second supply conduit 126 can provide the molten densifying agent 118 in a flow direction that is parallel to a portion of the ply stacks 134, 136, 164, 166 of the CMC preform 102. For example, as also described herein with respect to FIG. 3, the first section 160 including the inlet 132 can flow and / or supply the molten densifying agent 118 to the openings 110 in a second direction (D2) that can be substantially parallel to the predetermined unidirectional material orientation of the ply stack 134 to fill and / or infiltrate the voids 138 formed between the ply stacks 134 and 136. Additionally, the second section 162 of the second supply conduit 126 can include an inlet 168 that flows and / or supplies the molten densifying agent 118 in a fourth flow direction (D4). The fourth flow direction (D4) may not be exactly parallel to the predetermined unidirectional material orientation of the ply stack 164, but may be slightly angled (α) as a result of the configuration of the die set 104 and / or the second location 128 of the second supply conduit 126 of the die set 104. However, the fourth flow direction (D4) may be substantially closer to parallel (e.g., α=15° or less), such that the molten densifying agent 118 flowing from the second section 162 of the second supply conduit 126 in the fourth flow direction (D4) can more effectively and / or more efficiently flow and / or permeate through the voids 170 formed between the ply stacks 164, 166.

[0041] 9 illustrates another non-limiting example of the system 100. Specifically, the system 100 of FIG. 9 includes a molten densifying agent source 112 in communication only with the first supply conduit 120 and a separate molten densifying agent source 152 in communication only with the second supply conduit 126. Additionally, aside from the non-limiting example illustrated in FIG. 1, the first location 122 of the first supply conduit 120 may be formed within and / or on the first portion 106 of the die set 104. Specifically, the first location 122 of the first supply conduit 120 may be at and / or through a bottom 172 of the first portion 106 of the die set 104 adjacent the sidewall 130.

[0042] FIG. 10 illustrates an exemplary process for infiltrating a porous ceramic matrix composite (CMC) preform. More specifically, FIG. 10 illustrates a flow diagram illustrating a non-limiting example process for infiltrating and densifying a CMC preform with a molten densifier material. In some cases, the process can be used to form a CMC article from the infiltrated and densified CMC preform, as described herein with respect to FIGS. 1-9.

[0043] In process P1, a porous CMC preform can be positioned within an opening of a die set of an infiltration system used to perform the infiltration process. The CMC preform can include a plurality of ply stacks and a plurality of voids formed between each of the ply stacks. Each of the plurality of ply stacks can include a predetermined unidirectional material orientation. Positioning the CMC preform in the opening can also include aligning a predetermined unidirectional material orientation of at least one of the plurality of ply stacks of the CMC preform with a second flow direction of the flowing molten densifying agent.

[0044] In process P2, the molten densification agent can flow onto the CMC preform in a first flow direction. Specifically, the molten densification agent can flow onto the CMC preform in the first flow direction and infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform. The first flow direction can be substantially perpendicular to at least one predetermined unidirectional material orientation of the plurality of ply stacks forming the CMC preform. Flowing the molten densification agent in the first flow direction can also include supplying the molten densification agent onto the CMC preform in the first flow direction at a pressure equal to or greater than atmospheric pressure.

[0045] In process P3, the molten densification agent can flow onto the CMC preform in a second flow direction. Specifically, the molten densification agent can flow onto the CMC preform in a second flow direction and infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform. The second flow direction can be distinct from the first flow direction. In addition, the second flow direction can be substantially parallel to at least one predetermined unidirectional material orientation of the plurality of ply stacks forming the CMC preform. Flowing the molten densification agent in the second flow direction can also include supplying the molten densification agent onto the CMC preform in the second flow direction at a pressure equal to or greater than atmospheric pressure.

[0046] In process P4 (shown in phantom as optional), the molten densifying agent can flow onto the CMC preform in a third flow direction. Specifically, the molten densifying agent can flow onto the CMC preform in a third flow direction and infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform. The third flow direction can be distinct from the first flow direction. In a non-limiting example, the third flow direction can be the same as or distinct from the second flow direction. In addition, the third flow direction can be substantially parallel to a predetermined unidirectional material orientation of at least one distinct ply stack of the plurality of ply stacks forming the CMC preform. The distinct ply stacks identified in process P4 can be different or distinct from the ply stacks of process P3. Flowing the molten densifying agent in a third flow direction can also include supplying the molten densifying agent onto the CMC preform in the third flow direction at a pressure equal to or greater than atmospheric pressure.

[0047] In process P5, the rate and / or pressure of the molten densification agent can be controlled. More specifically, the rate and / or pressure of the molten densification agent flowing in a first direction (process P2), a second direction (process P3), and a third direction (process P4) over the CMC preform can be controlled and / or adjusted (e.g., increased, decreased, maintained) to assist in infiltration and / or densification of the CMC preform. The rate and / or pressure of the molten densification agent can be controlled using features positioned in and / or adjacent to the supply conduit of the infiltration system that flows and / or supplies the molten densification agent. The features may include, but are not limited to, an enlarged portion (e.g., an inlet) of the supply conduit, or an adjustable valve in communication with the supply conduit.

[0048] A technical effect of the present disclosure is to provide a method and system for flowing a molten densification agent parallel to a predetermined unidirectional material orientation of a ply stack of a porous ceramic matrix composite (CMC) preform to improve infiltration and / or densification of the CMC preform.

[0049] The above figures show some of the relevant processes according to some embodiments of the present disclosure. In this regard, each figure or block in the flow diagram of the figures represents a process related to the described method embodiment. It should also be noted that in some alternative implementations, the operations described in the figures or blocks may occur out of the order shown in the figures, or may actually be performed substantially simultaneously or in reverse order, depending on the operations involved, for example. Also, those skilled in the art will recognize that additional blocks describing the process may be added.

[0050] The terminology used herein is merely for the purpose of describing certain embodiments and is not intended to limit the disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural unless otherwise specified. It will be further understood that the terms "comprise" and / or "comprising" as used herein specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or sets thereof. "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and the description includes instances in which the event occurs and instances in which it does not occur.

[0051] As used herein throughout the specification and claims, approximation language can be applied to modify any quantitative expression that can be reasonably varied without causing a change in the basic function involved. Thus, values ​​modified by terms such as "approximately," "about," and "substantially" are not limited to the exact value specified. In at least some instances, approximation language can correspond to the precision of the instrument for measuring the value. Here, as well as throughout the specification and claims, range limitations can be combined and / or substituted, and such ranges are identified and include all subranges encompassed therein, unless the context and language dictate otherwise. "About," as applied to a particular value in a range, applies to both values ​​and can indicate + / - 10% of the stated value, unless specifically dependent on the precision of the instrument for measuring the value.

[0052] The corresponding structures, materials, acts, and equivalents of all means-plus-function or step-plus-function elements in the following claims are intended to encompass any structure, material, or act to perform that function in combination with other specifically claimed claim elements. The description of the present disclosure has been presented for purposes of illustration and description, and is not intended to be exhaustive or to limit the disclosure to the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the disclosure. The present embodiment has been chosen and described in order to best explain the principles and practical application of the disclosure, and to enable others skilled in the art to understand the disclosure in its various embodiments with various modifications as appropriate for the particular use envisaged. [Explanation of symbols]

[0053] 100 Systems 102 Porous Ceramic Matrix Composite (CMC) Preform 104 Die Set 106 First Part 108 Second Part 110 Opening 112 Source of molten densification agent 118 Melt densification agent 120 first molten densifying agent supply conduit 122 1st Place 124 Entrance 126 Second molten densifier supply conduit 128 Second Place 130 Side wall 132 Entrance, opening 134 Price Stack 136 Price Stack 138 Void 140 third molten densifying agent supply conduit 142 Third Place 144 Entrance 146 Side wall 148 Plunger 150 side wall 152 Separate source of molten densifier 154 Features 156 Enlarged section 158 Adjustable Valve 160 First Section 162 Second Section 164 Price Stack 166 Price Stack 168 Entrance 170 Void 172 Bottom D1 First flow direction D2 Second flow direction D3 Third flow direction D4 Fourth flow direction P1 Process P2 Process P3 Process P4 Process P5 Process

Claims

1. A method for infiltrating a porous ceramic matrix composite (CMC) preform (102), the method comprising: positioning (P1) the porous CMC preform (102) in an opening (110) of a die set (104) for an infiltration system (100), the CMC preform (102) including a plurality of ply stacks (134, 136), each of the plurality of ply stacks (134, 136) including a predetermined unidirectional material orientation, and a plurality of voids (138, 170) formed between each of the plurality of ply stacks (134, 136); flowing (P2) a molten densifying agent (118) from a source of molten densifying agent (112) in a first flow direction (D1) onto the porous CMC preform (102) through a first supply conduit (120) extending directly from a first opening on a first side of the source of molten densifying agent (112) to a first inlet location (122) of the die set (104) to infiltrate the plurality of voids (138, 170); flowing (P3) the molten densifying agent (118) from the molten densifying agent source (112) through a second supply conduit (126) extending directly from a second opening on a second side of the molten densifying agent source (112) to a second inlet location (128) of the die set (104) in a second flow direction (D2) distinct from the first flow direction (D1) to infiltrate the plurality of voids (138, 170); flowing (P4) the molten densifying agent (118) from the molten densifying agent source (112) through a third supply conduit (140) extending directly from a third opening on a third side of the molten densifying agent source (112) to a third inlet location (142) of the die set (104) in a third flow direction (D3) distinct from the first flow direction (D1) to infiltrate the plurality of voids (138, 170); Including, the second flow direction (D2) is substantially parallel to the predetermined unidirectional material orientation of at least one ply stack (134) of the plurality of ply stacks (134, 136) of the CMC preform (102); and the third flow direction (D3) being substantially parallel to the predetermined unidirectional material orientation of at least one distinct ply stack (134) of the plurality of ply stacks (134, 136) of the CMC preform (102); method.

2. 2. The method of claim 1, wherein the first flow direction (D1) is substantially perpendicular to the predetermined unidirectional material orientation of the at least one ply stack (134) of the plurality of ply stacks (134, 136) of the CMC preform (102).

3. A step (P1) of positioning the porous CMC preform (102) in the opening (110) of the die set (104) comprises:

2. The method of claim 1, comprising aligning the predetermined unidirectional material orientation of the at least one ply stack (134) of the plurality of ply stacks (134, 136) of the CMC preform (102) with the second flow direction (D2) of the flowing molten densifying agent (118).

4. A step (P2) of flowing the molten densifying agent (118) onto the porous CMC preform (102) in the first flow direction (D1), supplying said molten densifying agent (118) onto said porous CMC preform (102) in said first flow direction (D1) at a pressure equal to or greater than atmospheric pressure; The method of claim 1 further comprising:

5. A step (P3) of flowing the molten densifying agent (118) onto the porous CMC preform (102) in the second flow direction (D2), delivering said molten densifying agent (118) onto said porous CMC preform (102) in said second flow direction (D2) at a pressure greater than atmospheric pressure; The method of claim 1 further comprising:

6. The method of claim 1, wherein the first supply conduit (120), the second supply conduit (126) and the third supply conduit (140) are independent of one another, and the first inlet position (122), the second inlet position (128) and the third inlet position (142) of the die set (104) are independent of one another.

7. 2. The method of claim 1, wherein the first flow direction (D1) is substantially perpendicular to the predetermined unidirectional material orientation of the at least one distinct ply stack (134) of the plurality of ply stacks (134, 136) of the CMC preform (102).

8. The method of claim 1 , wherein the third flow direction (D3) is distinct from the second flow direction (D2).

9. A step (P4) of flowing the molten densifying agent (118) onto the porous CMC preform (102) in the third flow direction (D3), delivering said molten densifying agent (118) onto said porous CMC preform (102) in said third flow direction (D3) at a pressure greater than atmospheric pressure; The method of claim 1 further comprising:

10. Controlling (P5) the velocity of the molten densifying agent (118) flowing onto the porous CMC preform (102) in the first flow direction (D1); or Controlling (P5) the velocity of the molten densifying agent (118) flowing onto the porous CMC preform (102) in the second flow direction (D2). The method of claim 1 , further comprising at least one of:

Images