Silicide-Forming Alloy Infiltration for High-Temperature CMC Matrices
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Solution Overview
Problem
The melting temperature of silicon in silicon melt infiltrated ceramic matrix composite (CMC) components limits their use at higher temperatures, and higher temperature metals often damage the fibers during infiltration.
Innovation Solution
The use of eutectic and metal-rich alloys comprising silicon and constituents like zirconium, hafnium, tungsten, tantalum, molybdenum, niobium, and iridium, with melting points between 1,250°C to 1,650°C, for reactive infiltration to form a matrix that avoids fiber damage and allows higher temperature use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicon is used as the infiltrant material, then the CMC component can be fabricated with good fiber wetting and low processing temperature, but the melting temperature of silicon (2570°F/1410°C) limits the use temperature of the component
Solution Approach 1:
The patent changes the chemical composition parameters of the infiltrant material by using binary alloys (e.g., Mo-Si, W-Si, Ta-Si, Nb-Si, Hf-Si, Ir-Si) instead of pure silicon. This compositional modification allows tuning of the melting point while maintaining reactive infiltration capability, enabling use temperatures above 2570°F without fiber damage.
Solution Approach 2:
The patent employs composite infiltrant materials consisting of silicon combined with refractory metals (Mo, W, Ta, Nb, Hf, Ir). These composite alloys combine the low melting point and good wetting properties of silicon with the high temperature stability of refractory metals, achieving both low processing temperature and high use temperature capability.
2Temperature
If higher temperature metals are used as infiltrants to increase use temperature, then the component can operate at higher temperatures, but these metals have poor properties for CMCs and may damage fibers during infiltration
Solution Approach 1:
The patent modifies the physical and chemical parameters of the infiltrant by creating eutectic and metal-rich binary alloys. These alloy compositions have controlled melting points (2000°F-3000°F) that are high enough for elevated temperature service but low enough to maintain good fluidity and reactivity during infiltration, ensuring ease of manufacture.
Solution Approach 2:
The patent creates local compositional optimization by using metal-rich alloys where the refractory metal content is controlled to provide high temperature stability at the infiltration front, while silicon content ensures low melting point and good wetting. This local quality distribution enables both high use temperature and good processability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a matrix that withstands higher temperatures without damaging the fibers, with minimal residual free silicon, enhancing the CMC's heat tolerance and strength.
Implementation Method 1
either the at least one eutectic alloy or the at least one metal-rich alloy comprises a melting point range of approximately 1,250°C to approximately 1,650°C
Implementation Method 2
reacting either the at least one eutectic alloy constituent or the at least one metal-rich alloy constituent with the carbon source material; forming at least one matrix material within, around and in contact with the at least one ceramic fiber or the at least one ceramic fiber tow, the at least one matrix material comprising at least one eutectic alloy, at least one metal-rich alloy, and combinations thereof; wherein the at least one eutectic alloy or at least one metal-rich alloy comprises silicon and at least one of the following alloy constituents: zirconium, hafnium, tungsten, tantalum, molybdenum, niobium, and iridium
Data Source
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AI summary
A gas turbine engine component includes a component including at least one ceramic matrix composite material, the at least one ceramic matrix composite material further includes a ceramic fiber reinforcement containing at least one ceramic fiber or at least one ceramic fiber tow; and a matrix material disposed around and in contact with the at least one ceramic fiber or the at least one ceramic fiber tow; the matrix material contains at least one eutectic alloy, at least one metal-rich alloy, or combinations thereof; either the at least one eutectic alloy or the at least one metal-rich alloy includes silicon and at least one of the following alloy constituents: zirconium, hafnium, tungsten, tantalum, molybdenum, niobium, and iridium; and, either the at least one eutectic alloy or the at least one metal-rich alloy exhibits and possesses a melting point range of approximately 1,250°C to approximately 1,650°C.