Additive Manufacturing of Fiber-Reinforced Ceramic Matrix Composites
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Solution Overview
Problem
Current additive manufacturing techniques lack a reproducible and reliable method for producing fiber-reinforced ceramic matrix composites, particularly for gas turbine components, due to the similar melting points of matrix powder and solid fibers, which hinders the creation of complex internal structures and high-temperature durability.
Innovation Solution
A method involving selective laser melting or electron beam melting, where ceramic fibers are partly remelted and adhesively joined to a ceramic matrix by controlling energy beam parameters, allowing for the fabrication of ceramic matrix composites with maintained fiber properties and high adhesion, using a movable apparatus for precise fiber placement in the powder bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ceramic fiber is completely remelted during additive manufacturing, then the base material can be adhesively joined, but the fiber material is destroyed and loses its reinforcing properties
Solution Approach 1:
The patent applies local quality by using a movable apparatus to selectively place ceramic fibers only in specific regions of the powder bed where reinforcement is needed, rather than uniformly throughout. This allows the energy beam to remelt base material for adhesive joining while preserving fiber integrity in critical load-bearing areas, thus resolving the contradiction between achieving strong bonding and maintaining fiber reinforcing properties
Solution Approach 2:
The patent implements preliminary action by pre-positioning ceramic fibers in the powder bed before applying the energy beam for selective remelting. This sequence ensures that fibers are already in place to be bonded, allowing the energy beam to locally remelt the base material around fibers for adhesive joining without completely remelting and destroying the fiber structure, thereby maintaining both bonding strength and fiber reinforcing properties
2Ease of manufacture
If conventional additive manufacturing routes are used for CMC production, then manufacturing simplicity is maintained, but no reproducible and reliable manufacturing route exists due to similar melting points of matrix powder and solid fibers
Solution Approach 1:
The patent applies dynamics by introducing a movable apparatus that can dynamically position and place ceramic fibers into the powder bed during the additive manufacturing process. This dynamic fiber placement capability, combined with controlled energy beam parameters, enables reproducible and reliable manufacturing of CMCs by allowing adaptive adjustment of fiber positions and densities, while maintaining the simplicity of the additive manufacturing approach
Solution Approach 2:
The patent implements parameter changes by carefully controlling the energy beam parameters (such as power, speed, and focal position) to achieve selective remelting of the base material without completely remelting the ceramic fibers. This parameter control enables the process to be reproducible and reliable, distinguishing it from conventional routes while maintaining manufacturing simplicity through direct digital control
3Reliability
If the ceramic fiber is only partly remelted, then fiber properties are maintained, but adhesive joining to the matrix material is insufficient
Solution Approach 1:
The patent applies local quality by using the movable apparatus to selectively place fibers and control the energy beam to create localized remelting zones around the fibers. This local control allows the base material to be remelted for adhesive joining while the fiber core remains intact, achieving both good adhesion and fiber property maintenance through spatially differentiated processing
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
Enables the production of ceramic matrix composites with enhanced mechanical properties, high density, and reduced porosity, suitable for gas turbine applications, with improved design freedom and thermal resistance.
Implementation Method 1
A method of selective laser melting is described in EP 2 601 006 B1, for example
Implementation Method 2
electron beam melting (EBM)
Implementation Method 3
the base material is remelted, solidified and thereby adhesively joined to the ceramic fiber
Data Source
Figure 1~3
Figure 4~6
AI summary
The present invention relates to a method of additively manufacturing a ceramic matrix composite material (10) comprising providing a ceramic fiber (3) and a powdery base material (2) for a ceramic matrix composite and layer-by- layer building up the ceramic matrix material (5) for the ceramic matrix composite by irradiating of a powder bed formed by the base material (2) with an energy beam (6) according to a predetermined geometry, wherein the base material (2) is remelted, solidified and adhesively joined to the ceramic fiber (3) in that parameters of the energy beam (6) are locally chosen such that in the contact region (CR) of the ceramic fiber (3) and the powder bed, the ceramic fiber (3) is only partly remelted.