Ceramic Matrix Composite Component with Braided Core
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Solution Overview
Problem
Current methods for fabricating ceramic matrix composite (CMC) components, such as those used in gas turbine engines, face challenges in enhancing the strength and radial and torsional stiffness, particularly in the internal layers that contribute to the shape and structure of the components.
Innovation Solution
A ceramic matrix component is designed with a fibrous core having a three-dimensional braided structure and cooling passages, surrounded by a ceramic matrix composite shell, where the fibrous core is formed from carbon and ceramic fibers, and the method involves partial densification, pyrolysis to create passages, and chemical vapor infiltration to form the ceramic matrix, allowing for improved radial and torsional stiffness and uniform density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fabrication methods (MI, CVI, PIP) are used with fibrous preforms, then the component can be manufactured, but the internal layers lack sufficient strength and radial/torsional stiffness
Solution Approach 1:
The component is divided into distinct functional zones: a fibrous preform outer layer and an internal core with varying properties. This segmentation allows each zone to be optimized independently - the preform provides structural envelope while the internal core provides enhanced stiffness and strength through controlled porosity and fiber orientation.
Solution Approach 2:
The internal core is designed with non-uniform properties - higher density and fiber concentration in regions requiring strength, lower density in regions requiring cooling passages. This local variation in material quality allows simultaneous optimization of strength, stiffness, and cooling efficiency without compromising manufacturability.
2Strength
If the fibrous core is made denser to improve strength, then strength increases, but the ability to form cooling passages and achieve uniform density decreases
Solution Approach 1:
The fibrous core is partially densified before the final ceramic matrix infiltration process. This preliminary densification creates a scaffold that guides subsequent material deposition, ensuring uniform density distribution while preserving porosity for cooling passages. The partial densification prevents excessive density that would block passage formation.
Solution Approach 2:
The fibrous core is designed with controlled porosity to accommodate cooling passages while maintaining sufficient structural strength. The porous structure allows coolant flow through the core, and the porosity is optimized to balance strength requirements with passage formation capabilities.
3Temperature
If cooling passages are added to the fibrous core, then cooling efficiency improves, but structural integrity and density uniformity are compromised
Solution Approach 1:
The fibrous core is constructed as a composite of ceramic fibers and matrix material with controlled porosity. This composite structure provides both the structural integrity needed for load-bearing applications and the porous pathways required for efficient cooling. The ceramic matrix binds the fibers while allowing coolant flow through the porous network.
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 CMC components with enhanced strength and stiffness, along with efficient cooling passages, leading to more uniform density and improved structural integrity for gas turbine engine components.
Implementation Method 1
pyrolyzing the carbon fibers to form passages
Implementation Method 2
forming a ceramic matrix on the fibrous preform using chemical vapor infiltration
Data Source
AI summary
Disclosed is a ceramic matrix component having a fibrous core and a ceramic matrix composite shell surrounding at least a portion of the fibrous core. The fibrous core has a three dimensional braided structure and cooling passages. A method of making the ceramic matrix component is also disclosed.