Ceramic matrix composite component and manufacturing method including cooling channels in multiple plies

Abstract

To provide a ceramic matrix composite component and a method for manufacturing a ceramic matrix composite component that provides improved cooling for CMC gas turbine components when subjected to extreme conditions such as extreme thermal gradients and high temperatures. A ceramic matrix composite (CMC) component and method of fabrication includes one or more elongated functional features formed in a plurality of fiber plies of the CMC component. The CMC component includes a plurality of longitudinally extending ceramic matrix composite plies in a stacked configuration. Each of the one or more elongated functional features includes an inlet and an outlet to provide fluid flow from a fluid source to an exterior of the ceramic matrix composite component. The one or more elongated functional features are configured in a plurality of the longitudinally extending ceramic matrix composite plies to form a plurality of cooling channels within the plurality of plies of the ceramic matrix composite component.

Description

Technical Field

[0001] The present invention generally relates to gas turbines for power generation, and more particularly, to a method of forming ceramic matrix composite components for high temperature gas path turbine components of a gas turbine.

Background Art

[0002] Silicon carbide (SiC)-based ceramic matrix composite (CMC) materials have been proposed as materials for specific components of gas turbine engines, such as turbine blades, vanes, nozzles, shrouds, and buckets. Various methods for fabricating SiC-based components are known, including Silicomp, melt infiltration (MI), chemical vapor infiltration (CVI), polymer infiltration pyrolysis (PIP), and oxide / oxide methods. These fabrication techniques are quite different from each other, but each involves the use of handling and tooling or dies to produce near-net shape parts through methods that include heating at various stages of the process.

[0003] Similar to turbine blades and vanes formed from more common superalloy materials, CMC blades, vanes, and shrouds typically have cavities and cooling passages mainly for component weight reduction, centrifugal load reduction, and operating temperature reduction. These features are typically formed in CMC components using a combination of removable and disposable tools, or perforation. Internal cooling channels are advantageous for cooling both metal and CMC high temperature gas path hardware because they reduce cooling flow requirements and thermal gradients / stresses.

[0004] In many cases, CMC gas turbine components are subjected to extreme conditions in the form of extreme thermal gradients and high temperatures. Even if the CMC components have cavities or cooling vents as mentioned above, these extreme conditions can cause crack formation, coating fracture, and thinning of the CMC components. These problems shorten the operational life, preventing the CMC components from reaching their full potential.

[0005] Therefore, there is a need for ceramic matrix composite components and methods for manufacturing ceramic matrix composite components that provide improved cooling to CMC gas turbine components when subjected to extreme conditions such as extreme thermal gradients and high temperatures. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] U.S. Patent No. 10,384,981 [Overview of the project] [Means for solving the problem]

[0007] The aspects and benefits of this disclosure are partially described in the following description, can be made apparent from that description, or can be learned through the implementation of this disclosure.

[0008] A ceramic matrix composite (CMC) component is provided as a whole, along with a method for forming the component. In one embodiment, the ceramic matrix composite component includes a plurality of longitudinally extending ceramic matrix composite plies of a stacked configuration forming a dense body, and one or more elongated functional feature portions formed within the dense body. Each of the one or more elongated functional feature portions includes an inlet and an outlet. Each of the one or more elongated functional feature portions is configured to supply a fluid flow from a fluid source to the outside of the ceramic matrix composite component. Each of the one or more elongated functional feature portions is composed of a plurality of plies of the plurality of longitudinally extending ceramic matrix composite plies so as to form a plurality of cooling channels within the plurality of plies of the ceramic matrix composite component.

[0009] In an alternative embodiment, the ceramic matrix composite component includes a plurality of longitudinally extending ceramic matrix composite plies in a stacked configuration that form a dense body, and one or more elongated functional features formed on the plurality of longitudinally extending ceramic matrix composite plies. Each of the one or more elongated functional features is in fluid communication with one or more elongated functional features on another ply of the plurality of longitudinally extending ceramic matrix composite plies via one or more fluid connections. Each of the one or more elongated functional features includes an inlet and an outlet. The one or more elongated functional features define a plurality of cooling channels within the plurality of plies of the ceramic matrix composite component to carry a fluid flow from a fluid source to the outside of the ceramic matrix composite component.

[0010] In yet another embodiment, a method for forming a ceramic matrix composite (CMC) product includes the steps of: forming a CMC preform comprising a matrix precursor, a plurality of reinforcing fibers, and a plurality of sacrificial fibers; performing one of the steps of: removing the plurality of sacrificial fibers so that one or more elongated functional feature portions are formed within the plurality of fiber plies of the CMC preform, or applying a fluid impregnating agent to the CMC preform to densify the CMC preform; performing the other of the steps of: removing the plurality of sacrificial fibers so that one or more elongated functional feature portions are formed within the plurality of fiber plies of the CMC preform, or applying a fluid impregnating agent to the CMC preform to densify the CMC preform; and coupling one or more functional feature portions of the plurality of fiber plies of the CMC preform to a fluid-communicating state in order to form a plurality of cooling channels within the plurality of plies of the ceramic matrix composite component.

[0011] These and other features, aspects, and advantages of the Disclosure will be better understood by referring to the following description and the appended claims. The appended drawings are incorporated into and form part of this specification and serve to illustrate embodiments of the Disclosure and, together with this description, illustrate the principles of the Disclosure.

[0012] A complete and effective disclosure, including the best mode, is provided herein with reference to the accompanying drawings, intended for those skilled in the art. [Brief explanation of the drawing]

[0013] [Figure 1] This is a perspective view of a ceramic matrix composite (CMC) component, more particularly a portion of a CMC shroud, according to one or more embodiments disclosed herein. [Figure 2]This is a cross-sectional view of a portion of a ceramic matrix composite (CMC) component of Figure 1, viewed in the direction of 2-2 in Figure 1, according to one or more embodiments disclosed herein, showing a single CMC ply. [Figure 3] This is an isometric view of a portion of the ceramic matrix composite (CMC) component shown in Figure 2, according to one or more embodiments disclosed herein. [Figure 4] This is a cross-sectional view of a portion of a ceramic matrix composite (CMC) component of Figure 1, viewed in the direction of 4-4 in Figure 1, according to one or more embodiments disclosed herein, showing a single CMC ply. [Figure 5] This is an isometric view of a portion of the ceramic matrix composite (CMC) component shown in Figure 4, according to one or more embodiments disclosed herein. [Figure 6] Figures 4 and 5 are isometric views of the stacked configuration of the CMC plies according to one or more embodiments disclosed herein. [Figure 7] This is a simplified cross-sectional view taken through line 7-7 in Figure 6, according to one or more embodiments disclosed herein. [Figure 8] This is a cross-sectional view of a portion of another ceramic matrix composite (CMC) component showing a single CMC ply, according to one or more embodiments disclosed herein. [Figure 9] This is an isometric view of a portion of the ceramic matrix composite (CMC) component shown in Figure 8, according to one or more embodiments disclosed herein. [Figure 10] This is a cross-sectional view of a portion of another ceramic matrix composite (CMC) component showing a single CMC ply, according to one or more embodiments disclosed herein. [Figure 11] This is an isometric view of a portion of the ceramic matrix composite (CMC) component shown in Figure 10, according to one or more embodiments disclosed herein. [Figure 12]An isometric view of the CMC ply of FIGS. 8 and 10 in a stacked configuration according to one or more embodiments disclosed herein. [Figure 13] A simplified cross-sectional view taken through line 13-13 of FIG. 12 according to one or more embodiments disclosed herein. [Figure 14] A plan view of a portion of another ceramic matrix composite (CMC) component showing multiple CMC plies according to one or more embodiments disclosed herein. [Figure 15] A plan view of the CMC ply of FIG. 14 in a stacked configuration according to one or more embodiments disclosed herein. [Figure 16] A simplified cross-sectional view taken through line 16-16 of FIG. 15 according to one or more embodiments disclosed herein. [Figure 17] A plan view of a portion of another ceramic matrix composite (CMC) component showing multiple CMC plies according to one or more embodiments disclosed herein. [Figure 18] A plan view of the CMC ply of FIG. 17 in a stacked configuration according to one or more embodiments disclosed herein. [Figure 19] A simplified cross-sectional view taken through line 19-19 of FIG. 18 according to one or more embodiments disclosed herein. [Figure 20] A plan view of a portion of another ceramic matrix composite (CMC) component showing multiple CMC plies according to one or more embodiments disclosed herein. [Figure 21] A plan view of the CMC ply of FIG. 20 in a stacked configuration according to one or more embodiments disclosed herein. [Figure 22] A simplified cross-sectional view taken through line 22-22 of FIG. 21 according to one or more embodiments disclosed herein. [Figure 23]This is a schematic diagram of a method for forming a CMC component according to one or more embodiments disclosed herein. [Modes for carrying out the invention]

[0014] To the extent possible, use the same reference numeral to represent the same part throughout the drawing.

[0015] Embodiments of the present disclosure, compared to, for example, a concept that does not include one or more of the features disclosed herein, enable the formation of multiple cooling channels in multiple fiber faces or composite plies of a CMC component, and in a preferred embodiment, these channels are configured to be oriented with respect to each CMC ply. By incorporating the cooling channels into multiple fiber plies of the CMC component, the reduction in strength to any given ply is suppressed, while at the same time, the orientation of the channels can be changed without crossing multiple fibers. This cooling channel design makes the component more robust against thinning, maintains the structural integrity of the component, and reduces thermal stress by extending the channels through the CMC space. The method according to the present disclosure has a more efficient cooling that can reduce complexity at a low cost and reduce the cooling requirements and cooling flow rate of the component.

[0016] When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there is one or more of those elements. The terms “comprising,” “including,” and “having” are intended to include and mean that there may be additional elements other than those listed. Next, one or more examples of embodiments of the present disclosure shown in the drawings will be referenced in detail. Each example is presented to illustrate the present disclosure and not to limit it. Indeed, it will be apparent to those skilled in the art that various modifications and changes can be made in the present disclosure without departing from the scope or spirit of the present disclosure. For example, a feature illustrated or described as part of one embodiment can be used in conjunction with another embodiment to bring about further embodiments. Thus, it is intended that the present disclosure will encompass such modifications and changes within the scope of the appended claims and their equivalents.

[0017] Where in this disclosure a layer or ply is described as being “on” or “over” another layer or substrate, it will be understood that, unless expressly stated otherwise, those layers may be in direct contact with each other or may have another layer or feature between them. Thus, these terms merely describe the relative position of the layers relative to each other, and the relative position of being above or below depends on the orientation of the device to the viewer, so these terms do not necessarily mean being “on top of”.

[0018] Furthermore, when one layer or ply is described in this disclosure, it will be understood that multiple layers or pies may be formed in similar manner and having similar shapes, and stacked on top of each other to form what is commonly referred to as a ply pack.

[0019] Chemical elements are discussed in this disclosure using their common chemical abbreviations, such as those typically found in the periodic table of elements. For example, hydrogen is represented by its common chemical abbreviation H, helium by its common chemical abbreviation He, and so on.

[0020] In this book, "average particle diameter" or "average fiber diameter" refers to the diameter of particles or fibers such that approximately 50% of the particles or fibers have a diameter greater than that diameter, and approximately 50% of the particles or fibers have a diameter smaller than that diameter.

[0021] In this book, "substantially" refers to at least approximately 90% or more of the groups described. For example, "substantially all" means that at least approximately 90% or more of each group possess the characteristic, while "substantially none" or "substantially absent" means that at least approximately 90% or more of each group do not possess the characteristic. In this book, "the majority" refers to at least approximately 50% or more of the groups described. For example, "the majority" means that at least approximately 50% or more of each group possess the characteristic.

[0022] Ceramic matrix composite products ("CMC products"), particularly those formed by melt impregnation, along with methods for forming such products, are provided holistically in this document. The CMC products are formed from a plurality of plies or fibrous surfaces, each containing one or more elongated functional feature portions configured to enhance the functionality of the CMC, such as by forming a plurality of cooling channels or cooling circuits within the CMC preform.

[0023] Systems used for power generation include, but are not limited to, gas turbines, steam turbines, and other turbine assemblies used for power generation and aircraft engines, such as ground-based aerial turbines. In certain applications, power generation systems containing turbomachinery (e.g., turbines, compressors, and pumps) and other machinery may include components that are exposed to severe wear conditions. For example, certain power generation system components such as blades, buckets, casings, rotor wheels, shafts, shrouds, nozzles, and combustor liners may operate in high-temperature and / or high-speed environments. These components are manufactured using ceramic matrix composites, and these components may also include cooling passages. This disclosure provides CMC components that include multiple cooling passages or channels throughout the CMC component with multiple CMC plies or multiple fiber faces, and methods for forming ceramic matrix composite (CMC) components. Exemplary embodiments of this disclosure are shown in Figures 1 to 22 as part of a turbine shroud, but this disclosure is not limited to the illustrated structures.

[0024] Figure 1 is a perspective view of a component 10, such as a turbine shroud segment, but is not limited to this. Figure 1 shows a turbine shroud segment 12, but other preferred components according to this disclosure include, but are not limited to, combustor liners, blades, nozzles, nozzle end walls, shrouds, blade platforms, or other high-temperature gas passage components. Component 10 is preferably formed from a ceramic matrix composite (CMC) material. In this publication, ceramic matrix composite or "CMC" refers to a composite material comprising a ceramic matrix reinforced with ceramic fibers. Some examples of CMCs permissible in this publication include, but are not limited to, materials having a matrix and reinforcing fibers comprising oxides, carbides, nitrides, oxycarbides, oxynitrides, and mixtures thereof. Examples of non-oxide materials include, but are not limited to, CMC having a silicon carbide matrix and silicon carbide fibers (when produced by silicon melt impregnation, the matrix contains residual free silicon), CMC having a silicon carbide / silicon matrix mixture and silicon carbide fibers, CMC having a silicon nitride matrix and silicon carbide fibers, and CMC having a silicon carbide / silicon nitride matrix mixture and silicon carbide fibers. Furthermore, a CMC may have a matrix and reinforcing fibers made of oxide ceramics. In particular, oxide-oxide CMCs may consist of a matrix and reinforcing fibers containing oxide-based materials such as aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof. Therefore, in this book, the term "ceramic matrix composite" is not limited to carbon fiber reinforced carbon (C / C), carbon fiber reinforced silicon carbide (C / SiC), and silicon carbide fiber reinforced silicon carbide (SiC / SiC).In one embodiment, the ceramic matrix composite material exhibits improved ductility, fracture toughness, thermal shock, and anisotropy compared to an (unreinforced) monolithic ceramic structure.

[0025] Several methods can be used to fabricate SiC-SiC CMCs. In one method, the matrix is ​​partially formed or densified by molten impregnation (MI) of a CMC preform with molten silicon or silicon containing an alloy. In another method, the matrix is ​​at least partially formed by chemical vapor impregnation (CVI) of a CMC preform with silicon carbide. In a third method, the matrix is ​​at least partially formed by thermal decomposition of a preceramic polymer that becomes silicon carbide. This method is often referred to as polymer impregnation firing (PIP). The above three techniques can also be used in combination.

[0026] In one example of the MI CMC process, a boron nitride-based coating system is deposited onto SiC fibers. The coated fibers are then impregnated with a matrix precursor material to form a prepreg tape. One method of producing the tape is filament winding. The fibers are drawn through a bath of matrix precursor slurry, and the impregnated fibers are wound onto a drum. The matrix precursor can include silicon carbide and / or carbon nanoparticles, as well as organic materials. The impregnated fibers are then cut along the axis of the drum and removed from the drum to produce a flat prepreg tape in which the fibers are usually oriented in the same direction. The resulting material is a unidirectional prepreg tape. Prepreg tapes can also be made using a continuous prepreg machine or by other means. The tape is then cut into predetermined shapes, laid up, and laminated to produce a preform. The preform is pyrolysis or combustion to carbonize all organic material from the matrix precursor and to make it porous. Next, molten silicon is impregnated into the porous preform, where it can react with carbon to form silicon carbide. Ideally, excess free silicon fills all remaining pores, resulting in a high-density composite material. The matrix thus produced typically contains residual free silicon.

[0027] The prepreg MI process creates a material with a two-dimensional fiber structure where the fiber orientation changes between plies by stacking multiple one-dimensional prepreg plies on top of each other. Plies are often identified based on the continuous fiber orientation. A zero-degree orientation is established, and other plies are designed based on the angle of their fibers relative to the zero-degree direction. Plies in which the fibers extend perpendicular to the zero-degree direction are known as 90-degree plies, tolerance plies, or transverse plies.

[0028] MI techniques can also be used in two-dimensional or three-dimensional woven structures. An example of this technique is the slurry casting process, in which the fibers are first woven into a three-dimensional preform or a two-dimensional cloth. In the case of cloth, layers of cloth are cut into predetermined shapes and stacked to produce a preform. Chemical vapor impregnation (CVI) techniques are used to deposit interfacial coatings (typically boron nitride-based or carbon-based) onto the fibers. CVI can also be used to deposit layers of silicon carbide matrix. The remainder of the matrix is ​​formed by casting a matrix precursor slurry into the preform and then impregnating it with molten silicon.

[0029] An alternative to the MI method is to use CVI technology to densify silicon carbide matrices into one-dimensional, two-dimensional, or three-dimensional structures. Similarly, PIP can be used to densify the matrix of composite materials. Matrices produced by CVI and PIP can be produced without excess free silicon. Furthermore, MI, CVI, and PIP can be used in combination to densify matrices.

[0030] Multiple shroud segments 12 (of which only one is illustrated) define the shroud structure and are positioned concentrically with the rotor around which the turbine blades are attached. Generally, the shroud is produced in a ring shape, segmented, and then supplied to the end use as a set. As stated above, this disclosure is not intended to be limited to the specific shroud segments shown.

[0031] Each shroud segment 12 is generally made from multiple CMC plies (described shortly) and includes an arc-shaped shroud base 14 having axial components. A pair of upright ribs 18 and 20 are formed substantially perpendicular to the arc-shaped shroud base 14. The ribs 18 and 20 support the arc-shaped shroud base 14, and together they define cooling passages (described shortly) and chambers, such as chamber 22, within the shroud base 14. The ribs 18 and 20, and any optional flanges (not shown) included, help to mount the shroud segment 12 within the engine casing and mounting structure. Further cooling passages (not shown) may be located on the ribs 18 and 20. During operation of the power generation system, a flow of cooling air (not shown) is directed through the cooling passages in the shroud base 14 to lower the temperature of the shroud segment 12.

[0032] Typically, in a gas turbine engine, multiple stationary shroud segments, generally similar to the shroud segment 12, are assembled circumferentially around the axis of the axial-flow engine and radially outward around a rotating blade member, such as a turbine blade, defining a portion of the flow path boundary radially outward of the blade. Furthermore, assemblies of shroud segments are assembled axially in the engine between axially adjacent engine members, such as a nozzle and / or engine frame. The stationary shrouds confine combustion gases to a gas flow path so as to utilize the combustion gases with maximum efficiency to drive the gas turbine. The operating temperature of this flow path can exceed 500°C. The shroud segment 12, including a surface 28 that defines the inner diameter, is exposed to a high-temperature gas flow path that flows from the front of the shroud segment, indicated as collectively by reference numeral 11, to the rear of the shroud segment, indicated as collectively by reference numeral 13, as shown by arrow 26 throughout the drawing.

[0033] Next, referring to Figures 2 to 7, partial cross-sectional and isometric views of a portion of the component 10 of Figure 1 are shown. Figures 2 to 5 show alternating ceramic matrix composite (CMC) plies 34 of a stack 35 (Figures 6 and 7), where each ply 34 includes one or more elongated functional feature portions 30 formed internally. More specifically, a first fiber ply 36 consisting of multiple fibers (not shown) is shown in Figures 2 and 3, where the fiber ply 36 includes one or more elongated functional feature portions 30, more specifically, multiple cooling channels 32 (Figures 6 and 7). A second fiber ply 38 consisting of multiple fibers (not shown) is shown in Figures 4 and 5, where the fiber ply 38 includes one or more elongated functional feature portions 30, more specifically, multiple cooling channels 32 (Figures 6 and 7). When configured in a stack configuration as shown in Figures 6 and 7, one or more elongated functional feature portions 30 of the first and second fiber plies 36, 38 define a plurality of cooling channels 32 and a cooling circuit that pass through the component 10.

[0034] One or more elongated functional feature portions 30 are defined within each of several fiber plies 36, 38 using multiple sacrificial fibers. The fabrication of elongated functional feature portions using sacrificial fibers is described in U.S. Patent No. 10,384,981, entitled “Methods of Forming Ceramic Matrix Composites Using Sacrificial Fibers and Related Products,” filed concurrently with this application by the same assignor and incorporated herein, and in U.S. Patent Application No. 328251-1, entitled “Methods of Forming Ceramic Matrix Composites Using Sacrificial Fibers and Non-Wetting Coating,” filed concurrently with this application and incorporated herein.

[0035] As shown in Figure 7, the component 10 consists of a stack 35 of multiple ceramic matrix composite (CMC) plies, with only fiber plies 36 and 38 shown for clarity. Each of the fiber plies 36, 38 consists of multiple fibers 40, with only a few shown for clarity. In this particular embodiment, the fiber plies 36 and 38 are oriented at a 90° angle to each other with respect to the arrangement of the fibers 40 in each ply 36, 38. One or more elongated functional feature sections 30 in Figures 2 to 7 are in fluid communication with a plenum (not shown) via multiple inlets (to be described shortly) and with the outside of the component 10 via multiple outlets (to be described shortly). In an alternative embodiment, at least one of the one or more elongated functional feature sections 30 may be in fluid communication with an alternative source of cooling fluid (not shown).

[0036] Referring more closely to Figure 6, one or more elongated functional feature sections 30 are shown. One or more functional feature sections 30 form a complex network of interply fluid passages or cooling channels 32. Each of the cooling channels 32 includes an inlet 42 and an outlet 44. Each inlet 42 is in fluid communication with a cooling fluid source, such as a plenum (not shown) or an alternative source. Each outlet 44 is in fluid communication with the outside of the component 10.

[0037] Cooling fluid 46 flows through each cooling channel 32. As shown in the figure, multiple cooling channels 32 are configured in a multi-plane or multi-ply configuration to supply cooling fluid flow to each of the CMC plies 36, 38. In a preferred embodiment, the cooling channels 32 are configured to be oriented in accordance with the fibers 40 of each CMC ply 36, 38 in order to maintain the structural integrity of the component 10. By including the cooling channels 32 within the multiple fiber plies of the CMC component 10, a reduction in strength for any given ply is suppressed, while at the same time, the orientation of the channels can be changed without crossing the fibers 40. As described above, this design of cooling channels 32 makes the material more robust against thinning, maintains the structural integrity of the component, and reduces thermal stress by extending the cooling channels through the CMC space.

[0038] In the embodiments shown in Figures 1 to 7, the arrangement of the ceramic matrix composite plies 34 and cooling channels 32 is schematic and enlarged for illustrative purposes. The size and shape of the cavities, such as the CMC plies 34 and cooling channels 32, are not limited to those shown in Figures 1 to 7.

[0039] Next, referring to Figures 8 to 13, partial cross-sectional and isometric views of alternative embodiments of component 50 that are generally similar to component 10 in Figure 1 are shown. Figures 8 to 11 show alternating ceramic matrix composite (CMC) plies 34 of a stack 35 (Figures 12 and 13), each ply 34 containing one or more elongated functional feature portions 30 formed internally. More specifically, a first fiber ply 52 consisting of multiple fibers (not shown) is shown in Figures 8 and 9, each fiber ply 52 containing one or more elongated functional feature portions 30, more specifically, multiple cooling channels 32 (Figures 12 and 13). A second fiber ply 54 consisting of multiple fibers (not shown) is shown in Figures 10 and 11, each fiber ply 54 containing one or more elongated functional feature portions 30, more specifically, multiple cooling channels 32 (Figures 12 and 13). When configured in a stack configuration as shown in Figures 12 and 13, one or more elongated functional features of the first and second fiber plies 52, 54 define a plurality of cooling channels 32.

[0040] One or more elongated functional feature portions 30 are defined within each of the multiple fiber plies 52, 54 using multiple sacrificial fibers, as described above.

[0041] As shown in Figures 12 and 13, the component 50 consists of a stack 35 of multiple ceramic matrix composite (CMC) plies, with only fiber plies 52 and 54 shown for clarity. Each of the fiber plies 52 and 54 consists of multiple fibers 40, with only a few shown for clarity. In this particular embodiment, each of one or more functional feature portions 30 of the fiber ply 52 is in fluid communication with one or more functional feature portions 30 of the fiber ply 54 via a fluid connection portion 33 formed by one or more of laser drilling, electrical discharge machining, cutting, or machining of the ceramic matrix composite. One or more elongated functional feature portions 30 in Figures 8 to 13 are in fluid communication with a plenum (not shown) via multiple inlets (to be described shortly) and with the outside of the component 50 via multiple outlets (to be described shortly). In an alternative embodiment, at least one of the one or more elongated functional feature portions 30 may be in fluid communication with an alternative source of cooling fluid (not shown).

[0042] Referring more closely to Figure 12, one or more elongated functional feature sections 30 are shown. One or more functional feature sections 30 form a complex network of interply fluid passages or cooling channels 32. Each of the cooling channels 32 includes an inlet 42 and an outlet 44. Each inlet 42 is in fluid communication with a cooling fluid source, such as a plenum (not shown) or an alternative source. Each outlet 44 is in fluid communication with the outside of the component 50.

[0043] Cooling fluid 46 flows through each cooling channel 32. As shown in the figure, multiple cooling channels 32 are configured in a multi-plane configuration, supplying cooling fluid flow to each of the CMC plies 52 and 54. The cooling channels 32 are configured to be oriented in accordance with the fibers 40 of each CMC ply 52 and 54 in order to maintain the structural integrity of the component 50. Similar to the previously disclosed embodiment, the inclusion of the cooling channels 32 within multiple fiber plies of the CMC component 50 suppresses the reduction in strength for any given ply, while also allowing the orientation of the channels to be changed without crossing the fibers 40. As described above, this design of cooling channels 32 makes the material more robust against thinning, maintains the structural integrity of the component, and reduces thermal stress by expanding the channels through the CMC space.

[0044] In the embodiments shown in Figures 8 to 13, the arrangement of the ceramic matrix composite plies 34 and cooling channels 32 is schematic and enlarged for illustrative purposes. The size, number, and shape of the voids, such as the CMC plies 34 and cooling channels 32, are not limited to those shown in Figures 8 to 13.

[0045] Next, referring to Figures 14 to 16, schematic diagrams of another embodiment of a portion of component 60 that is generally similar to component 10 in Figure 1. More specifically, Figure 14 includes a top view of several prisms 34, which are generally similar to the prisms 34 in Figures 1 to 7 and are individually shown as prisms 62 to 74. Figure 15 is a schematic top view of component 60 showing one or more functional feature parts 30 that form a cooling circuit configuration. Figure 16 is a cross-sectional view of component 60 as seen in the direction 16-16 of Figure 15. Unless otherwise noted, component 60 includes the same components as those identified in the description of component 10 in Figures 1 to 7. Component 60 includes several cooling channels 32 that form a cooling circuit configuration similar to the embodiments in Figures 8 to 13, as previously mentioned. Similar to component 10, component 60 consists of several ceramic matrix composite (CMC) prisms 34, more specifically, individual prisms 62 to 74, each composed of several CMC fibers 40, each shown only a few times for clarity. In this particular embodiment, further CMC plies without functional feature portions are disclosed, as best shown in Figure 14. More specifically, Figure 14 shows seven individual plies, shown as 62–74, of which plies 64, 66, 70, and 72 include one or more elongated functional feature portions 30 formed internally. The plies 62–74 are configured in a stack 35, as shown in Figures 15 and 16, to fluidly connect one or more elongated functional feature portions 30 to define multi-face cooling channels 32 within the component 60. Each of the multi-face cooling channels 32 includes an inlet 42 and an outlet 44. In this particular embodiment, each of the one or more functional feature portions 30 of the fiber ply 64 is in fluid communication with one or more functional feature portions 30 of the fiber ply 66 via a fluid connection portion 33 formed directly during layup or by performing one or more of the following on the ceramic matrix composite material: laser drilling, electrical discharge machining, cutting, or machining.Furthermore, each of the one or more functional feature portions 30 of the fiber ply 70 is in fluid communication with one or more of the functional feature portions 30 of the fiber ply 72 via a fluid connection portion 33 that is formed directly during layup or by performing one or more of the following on the ceramic matrix composite material: laser drilling, electrical discharge machining, cutting, or machining. Each inlet 42 is in fluid communication with a cooling fluid source, such as a plenum (not shown) or an alternative source. Each outlet 44 is in fluid communication with the outside of the component 60. Cooling fluid 46 flows through each cooling channel 32. As shown in the figure, multiple cooling channels 32 are formed in multiple fiber plies or faces of the CMC preform or component 60.

[0046] In the embodiments shown in Figures 14-16, the arrangement of the ceramic matrix composite plies 62-74 and the cooling channels 32 is schematic and enlarged for illustrative purposes. The size, number, and shape of the voids, such as the CMC plies 62-74 and the cooling channels 32, are not limited to those shown in Figures 14-16.

[0047] Next, referring to Figures 17 to 19, schematic diagrams of another embodiment of a portion of component 80 that is generally similar to component 10 in Figure 1. More specifically, Figure 17 includes a top view of several prisms 34, which are generally similar to the prisms 34 in Figures 1 to 7 and are individually shown as prisms 82 to 94. Figure 18 is a schematic top view of component 80 showing one or more functional feature parts 30 that form a cooling circuit configuration. Figure 19 is a cross-sectional view of component 80 as seen in the direction 19-19 in Figure 18. Unless otherwise noted, component 80 includes the same components as those identified in the description of component 10 in Figures 1 to 7. Component 80 includes several cooling channels 32 that form a cooling circuit configuration similar to the embodiments in Figures 8 to 13, as described above. Similar to component 10, component 80 consists of several ceramic matrix composite (CMC) prisms 34, more specifically, individual prisms 82 to 94, each composed of several CMC fibers 40, each shown only a few times for clarity. In this particular embodiment, further CMC plies without functional feature portions are disclosed, as best shown in Figure 17. More specifically, Figure 17 shows seven individual plies, indicated as 82–94, of which alternating plies 84, 88, and 92 include one or more elongated functional feature portions 30 formed internally. The plies 82–94 are configured in a stack 35, as shown in Figures 18 and 19, to fluidly connect one or more elongated functional feature portions 30 to define multi-face cooling channels 32 within the component 80. Each of the multi-face cooling channels 32 includes an inlet 42 and an outlet 44. In this particular embodiment, each of the one or more functional feature portions 30 of the fiber ply 84 is in fluid communication with one or more functional feature portions 30 of the fiber ply 92 via a fluid connection portion 33 formed by performing one or more of the following on the ceramic matrix composite material: laser drilling, electrical discharge machining, cutting, or machining.Furthermore, each of the one or more functional feature portions 30 of the fiber ply 88 is in fluid communication with one or more functional feature portions 30 of the fiber ply 92 via a fluid connection portion 33 formed by one or more of laser drilling, electrical discharge machining, cutting, or machining of the ceramic matrix composite material. Each inlet 42 is in fluid communication with a cooling fluid source, such as a plenum (not shown) or an alternative source. Each outlet 44 is in fluid communication with the outside of the component 80. Cooling fluid 46 flows through each cooling channel 32. As shown in the figure, multiple cooling channels 32 are formed of multiple fiber plies or surfaces of the CMC preform or component 80.

[0048] In the embodiments shown in Figures 17-19, the arrangement of the ceramic matrix composite plies 82-94 and the cooling channels 32 is schematic and enlarged for illustrative purposes. The size, number, and shape of the voids, such as the CMC plies 82-94 and the cooling channels 32, are not limited to those shown in Figures 17-19.

[0049] Next, referring to Figures 20 to 22, schematic diagrams of another embodiment of a portion of component 100 that is generally similar to component 10 in Figure 1 are shown. More specifically, Figure 20 includes a top view of several prisms 34, which are generally similar to the prisms 34 in Figures 1 to 7 and are individually shown as prisms 102 to 112. Figure 21 is a schematic top view of component 100 showing one or more functional feature parts 30 that form a cooling circuit configuration. Figure 22 is a cross-sectional view of component 100 as seen in the direction of 22-22 in Figure 21. Unless otherwise noted, component 100 includes the same components as those identified in the description of component 10 in Figures 1 to 7. Component 100 includes several cooling channels 32 that form a z-shaped cooling circuit configuration. Similar to component 10, component 100 consists of several ceramic matrix composite (CMC) prisms 34, more specifically, individual prisms 102 to 112, each composed of several CMC fibers 40, each shown only a few times for clarity. In this particular embodiment, further CMC plies without functional feature portions are disclosed, as best shown in Figure 20. More specifically, Figure 20 shows six individual plies, indicated as 102-112, of which only plies 104-110 include one or more elongated functional feature portions 30 formed internally. The plies 102-112 are configured in a stack 35, as shown in Figures 21 and 22, to fluidly connect one or more elongated functional feature portions 30 to define multi-face cooling channels 32 within the component 100. More specifically, in this particular embodiment, each of the one or more functional feature portions 30 of fiber ply 104 is in fluid communication with one or more functional feature portions 30 of fiber ply 106 via fluid connections 33 formed directly during layup or by performing one or more of the following on the ceramic matrix composite material: laser drilling, electrical discharge machining, cutting, or machining.Furthermore, each of one or more functional feature portions 30 of the fiber ply 106 is in fluid communication with one or more functional feature portions 30 of the fiber ply 108 via fluid connection portions 33 formed directly during layup or by performing one or more of the following on the ceramic matrix composite material: laser drilling, electrical discharge machining, cutting, or machining. Each of the one or more functional feature portions 30 of the fiber ply 108 is in fluid communication with one or more functional feature portions 30 of the fiber ply 110. Each of the multiple cooling channels 32 includes an inlet 42 and an outlet 44. Each inlet 42 is in fluid communication with a cooling fluid source, such as a plenum (not shown) or an alternative source. Each outlet 44 is in fluid communication with the outside of the component 100. Cooling fluid 46 flows through each cooling channel 32. As shown in the figure, the multiple cooling channels 32 constitute multiple fiber plies or faces of the CMC preform or component 100.

[0050] In the embodiments shown in Figures 20-22, the arrangement of the ceramic matrix composite plies 34 and cooling channels 32 is schematic and enlarged for illustrative purposes. The size, number, and shape of the voids, such as the CMC plies 34 and cooling channels 32, are not limited to those shown in Figures 20-22.

[0051] Figure 23 schematically illustrates a method 200 for forming CMC components 10, 50, 60, 80, and 100 according to this disclosure, which have multiple fiber plies or one or more elongated functional feature portions 30 defined in a plane, more specifically, multiple cooling channels 32 formed to pass through multiple plies of the CMC component. Components 10, 50, 60, 80, and 100 are formed using a layup technique. Method 200 first includes the step of forming a CMC preform comprising a matrix precursor, multiple ceramic reinforcing fibers, and multiple sacrificial fibers in step 202. The step of forming the CMC preform first includes preparing multiple ceramic matrix composite plies 34, such as a series of plies 34 formed in a laminated stack. Examples of materials for the plies 34, but not limited to, include, as described above, prepreg composite plies comprising carbon fiber fabrics, binder materials, and coated SiC fibers.

[0052] As described above, the method, more specifically, step 202 of forming the CMC preform, includes means for defining one or more elongated functional features within the ply 34, such as by using multiple sacrificial fibers. The sacrificial fibers enable the formation of one or more elongated functional features 30 to enhance the function of the CMC, such as multiple cooling channels 32 within the CMC preform. The fabrication of elongated functional features using sacrificial fibers is discussed in U.S. Patent Application No. 10,384,981 and PTA Proceedings No. 328251-1, which are the same applicant and assignee as referenced above. The shape of the one or more elongated functional features 30 defined within the CMC preform includes any suitable shape, including rounded, curved, elliptical, straight, or other suitable shapes.

[0053] Further plies 34 are arranged to surround the sacrificial fibers. The preform components are placed in an autoclave and an autoclave cycle is completed to form a CMC preform containing matrix precursors, multiple ceramic reinforcing fibers, and multiple sacrificial fibers. The preform components undergo typical autoclave pressure and temperature cycles used in ceramic composite materials in the industry. Autoclave treatment extracts any volatile substances remaining in the plies, and autoclave conditions can be varied depending on the ply material. After autoclave treatment, a burnout process is performed to remove any remaining material or further binders in the preform components. The burnout process is generally performed at temperatures of approximately 426–648°C (approximately 800–1200°F).

[0054] After burnout, in step 204, the preform components are placed in a vacuum furnace for densification. Densification is carried out using any known densification technique, including, but not limited to, Silicomp, molten impregnation (MI), chemical vapor impregnation (CVI), polymer impregnation firing (PIP), and oxide / oxide methods. Densification can be carried out in a vacuum furnace in an established atmosphere at a temperature above 1200°C so that silicon or other impregnation material can be molten impregnated into the preform components. One preferred densification method is molten impregnation, in which case the molten matrix material can be drawn into the ply 34 and solidified. After densification, the densified preform components or dense bodies contain a plurality of sacrificial fibers positioned inside, as shown in step 204, forming at least a portion of components 10, 50, 60, 80, and 100.

[0055] Following densification, one or more elongated functional feature portions 30 are further formed in step 206 by removing sacrificial fibers to define cooling channels 32, leaving a plurality of elongated channels behind. Removing sacrificial fibers to form elongated channels is discussed in U.S. Patent Application No. 10,384,981 and PTA Proceedings No. 328251-1, which are the same applicant and assignee as referenced above.

[0056] In an alternative embodiment, one or more elongated functional feature portions 30 are further formed by removing a plurality of sacrificial fibers before densification as described in step 204, leaving a plurality of channels 32 behind.

[0057] In one embodiment, the internal hollow portion of one or more elongated functional feature portions 30 is sufficiently large and open within the components 10, 50, 60, 80, 100 to allow a coolant or other fluid to pass through the components 10, 50, 60, 80, 100 and cool them. However, the densified matrix material formed in the ceramic matrix composite ply 34 may form a sealing portion that substantially obstructs the flow of the coolant or other fluid, and more specifically, one or more elongated functional feature portions 30 form a closed structure inside the components 10, 50, 60, 80, 100. In one embodiment, openings are machined or otherwise formed in the components 10, 50, 60, 80, 100 to provide inlets 42 and / or outlets 44 for each of the one or more elongated functional feature portions 30 so that fluid can flow through them.

[0058] Accordingly, a CMC component is disclosed, comprising a CMC preform in which one or more functional features are formed within a plurality of fiber plies or planes. By forming one or more functional features in one or more fiber plies or planes, or in a CMC ply, a cooling channel network or cooling circuit is formed in a plurality of fiber plies or planes, while suppressing the reduction in strength of any given ply and allowing the orientation of the cooling channels to be changed without cutting the CMC fibers. As mentioned above, this cooling circuit design makes it more robust against thinning and reduces the need to widen the cooling channels within the CMC preform. Thermal disadvantages are minimized due to the relatively high conductivity of the CMC material.

[0059] One or more functional features are formed on the CMC components during layup and oriented with the CMC fibers of each ply. In the simplest embodiment, one or more functional features are oriented with the fibers of each ply in a plurality of plies arranged in alternately oriented plies. In more complex configurations, one or more functional features may form a complex network of interply fluid passages. These interply fluid passages may or may not be directly connected during layup, or they may be connected by laser drilling or other methods.

[0060] While the present invention has been described with reference to one or more embodiments, it will be understood by those skilled in the art that various modifications can be made without departing from the scope of the invention, and that equivalents can be substituted for elements of the invention. Furthermore, many modifications can be made to adapt the teachings of the invention to specific situations or materials without departing from the essential scope of the invention. Thus, the invention is not limited to the specific embodiments disclosed as the best possible mode for carrying out the invention, but is intended to include all embodiments that fall within the scope of the appended claims.

[0061] Further aspects of the present invention are presented by the subject matter of the following sections.

[0062] [Section 1] A ceramic matrix composite component, Multiple longitudinally extending ceramic matrix composite plies form a dense body, One or more elongated functional feature parts formed within a dense body Equipped with, Each of the one or more elongated functional features includes an inlet and an outlet, and the one or more elongated functional features are configured to supply a fluid flow from a fluid source to the outside of the ceramic matrix composite component. One or more elongated functional feature portions are configured in multiple plies of multiple longitudinally extending ceramic matrix composite components such that they form multiple cooling channels within multiple plies of the ceramic matrix composite component. Ceramic matrix composite component.

[0063] [Section 2] A ceramic matrix composite component according to any of the preceding items, wherein one or more elongated functional features are surrounded within a dense body.

[0064] [Section 3] A ceramic matrix composite component according to any of the preceding items, wherein multiple cooling channels define a z-shaped cooling circuit configuration.

[0065] [Section 4] A ceramic matrix composite component according to any of the preceding items, wherein each of the one or more elongated functional features of each of the multiple longitudinally extending ceramic matrix composite plies is in fluid communication with one or more elongated functional features of another ply of the multiple longitudinally extending ceramic matrix composite plies via one or more fluid connections.

[0066] [Section 5] A ceramic matrix composite component according to any of the preceding items, wherein one or more fluid connections are formed by performing one or more of the following on the ceramic matrix composite: laser drilling, electrical discharge machining, cutting, or machining.

[0067] [Section 6] A ceramic matrix composite component according to any of the preceding items, wherein one or more fluid connections include one or more laser-perforated fluid connections.

[0068] [Section 7] A ceramic matrix composite component according to any of the preceding items, wherein one or more fluid connections are formed during the layup of a plurality of longitudinally extending ceramic matrix composite plies.

[0069] [Section 8] A ceramic matrix composite component according to any of the preceding items, wherein multiple longitudinally extending ceramic matrix composite plies are pre-impregnated ceramic matrix composite plies.

[0070] [Section 9] A ceramic matrix composite component, as described in any of the preceding items, which is a component of a high-temperature gas passage turbine.

[0071] [Section 10] A ceramic matrix composite component as described in any of the preceding sections, wherein the high-temperature gas passage turbine component is selected from the group consisting of combustor liners, blades, shrouds, nozzles, nozzle end walls, and blade platforms.

[0072] [Section 11] A ceramic matrix composite component, Multiple longitudinally extending ceramic matrix composite plies form a dense body, One or more elongated functional feature portions formed on multiple plies of a ceramic matrix composite material ply extending in multiple longitudinal directions, each of which is in fluid communication with one or more elongated functional feature portions of another ply of the ceramic matrix composite material ply extending in multiple longitudinal directions via one or more fluid connection portions. Equipped with, Each of the one or more elongated functional features includes an inlet and an outlet, and each of the one or more elongated functional features defines multiple cooling channels within multiple plies of the ceramic matrix composite component so as to carry a fluid flow from a fluid source to the outside of the ceramic matrix composite component. Ceramic matrix composite component.

[0073] [Section 12] A ceramic matrix composite component according to any of the preceding items, wherein one or more fluid connections are formed by performing one or more of the following on the ceramic matrix composite: laser drilling, electrical discharge machining, cutting, or machining.

[0074] [Section 13] A ceramic matrix composite component according to any of the preceding items, wherein one or more fluid connections are formed during the layup of a plurality of longitudinally extending ceramic matrix composite plies.

[0075] [Section 14] A ceramic matrix composite component, as described in any of the preceding items, which is a component of a high-temperature gas passage turbine.

[0076] [Section 15] A ceramic matrix composite component as described in any of the preceding sections, wherein the high-temperature gas passage turbine component is selected from the group consisting of combustor liners, blades, shrouds, nozzles, nozzle end walls, and blade platforms.

[0077] [Section 16] A method for forming ceramic matrix composite (CMC) products, A step of forming a CMC preform comprising a matrix precursor, multiple reinforcing fibers, and multiple sacrificial fibers, The steps include removing multiple sacrificial fibers so that one or more elongated functional feature portions are formed within multiple fiber plies of the CMC preform, or A step of applying a fluid impregnating agent to a CMC preform, thereby densifying the CMC preform. A step of performing one of the following, The steps include removing multiple sacrificial fibers so that one or more elongated functional feature portions are formed within multiple fiber plies of the CMC preform, or A step of applying a fluid impregnating agent to a CMC preform, thereby densifying the CMC preform. The step of performing the other of the two, The steps include: forming cooling channels within multiple plies of a ceramic matrix composite component by coupling one or more functional feature portions of multiple fiber plies of a CMC preform into a fluid-communicating state; A method that includes this.

[0078] [Section 17] The method according to any of the preceding items, wherein the step of joining one or more functional feature portions of multiple fiber plies is performed by a method selected from the group consisting of laser drilling, electrical discharge machining, cutting, and machining.

[0079] [Section 18] The method according to any of the preceding items, wherein the fluid impregnating agent is silicon or a silicon alloy.

[0080] [Section 19] The method according to any of the preceding items, wherein the ceramic matrix composite component is a high-temperature gas passage turbine component.

[0081] [Section 20] The method according to any of the preceding items, wherein the high-temperature gas passage turbine components are selected from the group consisting of combustor liners, blades, shrouds, nozzles, nozzle end walls, and blade platforms. [Explanation of Symbols]

[0082] 10 Components 11. Front of the shroud segment 12 Turbine Shroud Segments 13 Rear of the shroud segment 14 Shroud base 18 Ribs 20 Ribs 22 Chambers 26 High-temperature gas flow path 28 Surface 30 Functional Features Section 32 cooling channels 33 Fluid connection section 34 Ceramic Matrix Composite (CMC) Ply 35 stacks 36 fiber plies, CMC plies 38 fiber plies, CMC plies 40 fibers 42 Entrance 44 Exit 46 Cooling fluid 50 components 52 fiber plies, CMC plies 54 Fiber plies, CMC plies 60 components 62 plies, lamic matrix composite plies, CMC plies 64 plies, lamic matrix composite plies, CMC plies 66 plies, lamic matrix composite plies, CMC plies 68 plies, lamic matrix composite plies, CMC plies 70 plies, lamic matrix composite plies, CMC plies 72 plies, lamic matrix composite plies, CMC plies 74 plies, lamic matrix composite plies, CMC plies 80 components 82 plies, lamic matrix composite plies, CMC plies 84 plies, lamic matrix composite plies, CMC plies 86 plies, lamic matrix composite plies, CMC plies 88 plies, lamic matrix composite plies, CMC plies 90 plies, lamic matrix composite plies, CMC plies 92 plies, lamic matrix composite plies, CMC plies 94 plies, lamic matrix composite plies, CMC plies 100 components 102 ply 104 ply, fiber ply 106 ply, fiber ply 108 ply, fiber ply 110 ply, fiber ply 112 plies 200 ways

Claims

1. A ceramic matrix composite component, Multiple longitudinally extending ceramic matrix composite plies form a dense body, One or more elongated functional feature portions formed within the ceramic matrix composite ply Equipped with, The one or more elongated functional feature portions are configured in multiple plies of the multiple longitudinally extending ceramic matrix composite material so as to form multiple cooling channels within the multiple plies of the ceramic matrix composite material component, Each of the plurality of cooling channels includes an inlet and an outlet and is configured to supply a fluid flow from a fluid source to the outside of the ceramic matrix composite component, defining a z-shaped cooling circuit configuration. A ceramic matrix composite component wherein each of the one or more elongated functional feature portions of the plurality of longitudinally extending ceramic matrix composite plies is in fluid communication with one or more elongated functional feature portions of another ply of the plurality of longitudinally extending ceramic matrix composite plies via one or more fluid connection portions.

2. The ceramic matrix composite component according to claim 1, wherein one or more elongated functional feature portions are surrounded within the dense body.

3. A ceramic matrix composite component, Multiple longitudinally extending ceramic matrix composite plies form a dense body, One or more elongated functional feature portions formed within the ceramic matrix composite ply Equipped with, The one or more elongated functional feature portions are configured in multiple plies of the multiple longitudinally extending ceramic matrix composite material so as to form multiple cooling channels within the multiple plies of the ceramic matrix composite material component, Each of the plurality of cooling channels includes an inlet and an outlet and is configured to supply a fluid flow from a fluid source to the outside of the ceramic matrix composite component. A ceramic matrix composite component wherein each of the one or more elongated functional feature portions of the plurality of longitudinally extending ceramic matrix composite plies is in fluid communication with one or more elongated functional feature portions of another of the plurality of longitudinally extending ceramic matrix composite plies via one or more fluid connection portions.

4. A ceramic matrix composite component according to claim 1, which is a component of a high-temperature gas passage turbine.

5. The ceramic matrix composite component according to claim 4, wherein the high-temperature gas passage turbine component is selected from the group consisting of a combustor liner, blades, shrouds, nozzles, nozzle end walls, and blade platforms.

6. A ceramic matrix composite component, Multiple longitudinally extending ceramic matrix composite plies form a dense body, One or more elongated functional feature portions formed on multiple plies of a ceramic matrix composite material ply extending in multiple longitudinal directions, each of which is in fluid communication with one or more elongated functional feature portions of another ply of the ceramic matrix composite material ply extending in multiple longitudinal directions via one or more fluid connection portions. Equipped with, Each of the one or more elongated functional feature portions formed in each of the plurality of plies defines a plurality of cooling channels within the plurality of plies of the ceramic matrix composite component, such that the fluid flow from the fluid source is carried to the outside of the ceramic matrix composite component. Each of the plurality of cooling channels includes an inlet and an outlet. Ceramic matrix composite component.

7. A ceramic matrix composite component according to claim 6, which is a component of a high-temperature gas passage turbine.

8. The ceramic matrix composite component according to claim 7, wherein the high-temperature gas passage turbine component is selected from the group consisting of a combustor liner, blades, shrouds, nozzles, nozzle end walls, and blade platforms.

9. A method for forming ceramic matrix composite (CMC) products, A step of forming a CMC preform comprising a matrix precursor, multiple reinforcing fibers, and multiple sacrificial fibers, The steps include removing the plurality of sacrificial fibers so that one or more elongated functional feature portions are formed within the plurality of fiber plies of the CMC preform, or A step of applying a fluid impregnating agent to the CMC preform, thereby densifying the CMC preform. A step of performing one of the following, The steps include removing the plurality of sacrificial fibers so that one or more elongated functional feature portions are formed within the plurality of fiber plies of the CMC preform, or A step of applying a fluid impregnating agent to the CMC preform, thereby densifying the CMC preform. The step of performing the other of the two, To form multiple cooling channels within multiple plies of a ceramic matrix composite component, the steps include: coupling one or more elongated functional feature portions of the multiple fiber plies of the CMC preform to one or more elongated functional feature portions of other plies of the multiple longitudinally extending ceramic matrix composite plies via one or more fluid connection portions; Methods that include...

10. The step of joining one or more elongated functional feature portions of multiple fiber plies is a method selected from the group consisting of laser drilling, electrical discharge machining, cutting, and machining. The method according to claim 9, wherein the method is as described above.

11. The method according to claim 9, wherein the fluid impregnating agent is silicon or a silicon alloy.

12. The ceramic matrix composite component is a high-temperature gas passage turbine component. The method according to claim 10.

13. The method according to claim 12, wherein the high-temperature gas passage turbine components are selected from the group consisting of a combustor liner, blades, shrouds, nozzles, nozzle end walls, and blade platforms.

Images