Ceramic Composite Core Structure for Lightweight CMC Bonding
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Solution Overview
Problem
Current ceramic matrix composite (CMC) materials for aerospace structures are bulky, expensive, and have limited bonding areas, especially in composite panels with internal cellular structures, leading to high material usage and potential structural weaknesses.
Innovation Solution
A pliable matrix material is used to bond ceramic core structures with CMC face sheets, accommodating dimensional mismatches and enhancing bonding capabilities, while utilizing additive manufacturing to create a monolithic ceramic core structure with optimized thermal conductivity and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional CMC materials are used for aerospace structures, then structural integrity is achieved, but weight increases and material cost increases
Solution Approach 1:
The component is divided into two distinct parts: a ceramic core structure providing structural integrity and CMC face sheets providing thermal and mechanical protection. This segmentation allows each material to perform its optimal function while reducing overall material usage and weight compared to traditional bulk CMC constructions.
Solution Approach 2:
The invention uses a composite structure combining ceramic core material with CMC face sheets. This composite approach leverages the high strength-to-weight ratio of ceramics for the core and the thermal shock resistance of CMC for the face sheets, achieving superior performance while reducing weight compared to monolithic CMC components.
2Ease of manufacture
If traditional bonding methods are used for composite panels, then assembly is achieved, but bonding area is limited and structural weaknesses occur
Solution Approach 1:
The ceramic core structure and CMC face sheets are merged into an integrated composite component through controlled bonding. This merging creates a unified structure where the bonding interfaces are optimized for both area and strength, eliminating the structural weaknesses associated with traditional limited bonding areas while maintaining manufacturing feasibility.
3Reliability
If more CMC material is used to increase bonding area, then bonding capability improves, but material cost increases and weight increases
Solution Approach 1:
Instead of uniformly increasing CMC material throughout the component, the invention applies CMC face sheets specifically at the bonding interfaces and critical structural zones. This local quality approach maximizes bonding capability and structural performance where needed while minimizing overall material usage and cost in non-critical areas.
Data Source
AI summary
A ceramic composite component includes a ceramic core structure having a plurality of hollow cells defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure. A ceramic matrix composite (CMC) structure is coupled to the ceramic core structure and includes a plurality of CMC plies. The CMC structure is defined by a first side of the CMC structure and a second side of the CMC structure, the second side of the CMC structure opposite the first side of the CMC structure. A first CMC face sheet is bonded to the first side of the ceramic core structure and the first side of the CMC structure. A second CMC face sheet is bonded to the second side of the ceramic core structure and the second side of the CMC structure.