Integrated Barrier Layer in CMC Components to Resist Cracking

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Solution Overview

Problem

Conventional coatings for ceramic matrix composite (CMC) components in gas turbine engines are susceptible to cracking, delamination, and environmental degradation, reducing their effectiveness and lifetime due to exposure to high temperatures and corrosive conditions.

Innovation Solution

An integrated barrier layer is formed within the ceramic-based matrix of CMC articles by infiltrating the barrier layer into voids created by removing fugitive fibers or porosity, providing a dense, integrated zone that extends beyond the matrix surface, incorporating gettering and diffusive particles to protect against oxidation and moisture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional coatings are applied to CMC components, then environmental protection is provided, but the coatings are susceptible to cracking, delamination, and environmental degradation

Engineering Contradiction:

Improvecoating effectivenessVSAvoidcracking and delamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The barrier layer is integrated directly into the CMC structure by infiltrating it into the matrix and voids, merging the protective function with the structural material rather than applying it as a separate conventional coating layer

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The barrier layer incorporates gettering particles and diffusive particles within a ceramic matrix, creating a composite material that provides enhanced environmental protection through multiple mechanisms (gettering of oxidants and diffusion barrier properties)

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If a barrier layer is applied to protect against oxidation, then oxidative stability is improved, but the barrier layer may crack and delaminate under thermal stress

Engineering Contradiction:

Improveoxidative stabilityVSAvoidcoating integrity

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The barrier layer is merged with the CMC structure through infiltration into the matrix and voids, creating an integrated zone that is mechanically bonded to the substrate, preventing delamination while maintaining oxidative stability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The barrier layer is applied selectively to different regions of the CMC component, with the integrated zone formed within the matrix bounds and a top zone extending beyond, providing localized protection where needed most

Inventive Principle:

Principle #3Local quality

3Reliability

If the barrier layer is infiltrated into voids to create an integrated zone, then delamination is reduced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvecoating adhesionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Voids are created in advance by removing fugitive reinforcements before the barrier layer is applied, allowing the barrier layer to be infiltrated into pre-formed cavities that enhance mechanical interlocking and adhesion

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The barrier layer serves as an intermediary material that infiltrates the voids and bonds to both the CMC matrix and the surface, creating a transition zone that improves adhesion between the protective layer and the substrate

Inventive Principle:

Principle #24Intermediary (Mediator)

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 integrated barrier layer enhances the environmental and thermal protection of CMC components by reducing cracking and delamination, offering improved resistance to oxidants and enhancing the oxidative stability of the underlying CMC components.

Implementation Method 1

applying a barrier layer to the ceramic matrix composite article such that at least some of the barrier layer infiltrates into voids in the ceramic matrix composite article

Methodology Applied

Scientific EffectInfiltration:

Implementation Method 2

the barrier layer includes gettering particles

Methodology Applied

Scientific EffectGettering: Gettering

Implementation Method 3

incorporating gettering and diffusive particles to protect against oxidation and moisture

Methodology Applied

Scientific EffectDiffusion barrier: Diffusion Barrier

Data Source

PatentUS20250388516A1Composite component with environmental protection

Publication Date: 2025.12.25 RTX CORP

AI summary

An article includes a ceramic matrix composite article including ceramic-based reinforcements disposed in a ceramic-based matrix and a barrier layer present at least in part within bounds of the ceramic-based matrix of the ceramic matrix composite article. A method of applying a barrier layer to an article is also disclosed.