Ceramic matrix composite materials with rare earth phosphate fibers and methods for preparing the same

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Solution Overview

Problem

Ceramic matrix composite materials degrade when exposed to temperatures above 1200 °C in oxidizing environments, such as those encountered in the gas turbine engine industry, due to passive and/or active oxidation.

Innovation Solution

Incorporating rare earth phosphate ceramic fibers into the reinforcing fiber structure and optionally the ceramic matrix, manufactured using a sol-gel process, to enhance resistance to oxidation and degradation at high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional CMC materials are used, then they provide good mechanical properties and creep resistance, but they exhibit passive and/or active oxidation and degradation at temperatures above 1200 °C in oxidizing environments

Engineering Contradiction:

Improveoxidation resistanceVSAvoiddegradation in oxidizing environment

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining rare earth phosphate fibers with conventional ceramic matrix materials. The rare earth phosphate fibers (containing phosphates such as LaPO4, YPO4, CePO4, or their solid solutions) are integrated into the ceramic matrix to form a composite structure that provides oxidation resistance at high temperatures while maintaining mechanical properties. This composite approach allows the material to benefit from both the structural integrity of the ceramic matrix and the oxidation protection of rare earth phosphate fibers.

Inventive Principle:

Principle #40Composite materials

2Reliability

If rare earth phosphate fibers are incorporated into the CMC material, then oxidation resistance at high temperatures is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveoxidation resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the fiber reinforcement function with the oxidation protection function by using rare earth phosphate fibers that serve dual purposes: they provide structural reinforcement like conventional ceramic fibers and simultaneously provide oxidation resistance through their chemical composition. This merging of functions reduces the need for separate protective coatings or treatments, thereby simplifying the overall manufacturing process despite the specialized nature of the fibers.

Inventive Principle:

Principle #5Merging (Combining)

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 resulting ceramic matrix composite material effectively resists oxidation and degradation at temperatures exceeding 1200 °C, making it suitable for high-temperature industrial applications like gas turbine engine components.

Implementation Method 1

manufactured using a sol-gel process

Methodology Applied

Scientific EffectSol-gel process: Sol

Implementation Method 2

effectively resists oxidation and degradation at temperatures exceeding 1200 °C

Methodology Applied

Scientific EffectOxidation resistance: Oxidation

Data Source

PatentEP3141536B1Ceramic matrix composite materials with rare earth phosphate fibers and methods for preparing the same

Publication Date: 2017.12.13 HONEYWELL INTERNATIONAL INC

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AI summary

Disclosed is a ceramic matrix composite (CMC) material including rare earth phosphate ceramic fibers embedded in a ceramic matrix, wherein the ceramic matrix also optionally includes a rare earth phosphate material. Methods for manufacturing the CMC material and gas turbine engine components formed of the CMC material are also disclosed.