Ceramic Matrix Composite Blade Internal Passage Sealing
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Solution Overview
Problem
Current methods for forming ceramic matrix composite (CMC) components, such as turbine blades, are labor-intensive and prone to damage due to the fragility of components during assembly, especially when creating internal passages or cavities, which requires multiple steps and the use of meltable mandrels that need to be removed and tip caps formed from multiple plies.
Innovation Solution
A method that uses ceramic foam to cap internal passages within CMC components, eliminating the need for additional lay-up steps and tools by forming a barrier layer that allows ceramic foam to fill and seal the passages, thereby reducing assembly complexity and avoiding the fragility issues associated with handling multiple plies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods using meltable mandrels and multiple CMC plies are used to form internal passages, then internal passages can be created, but the process becomes labor-intensive and the components become fragile during assembly
Solution Approach 1:
The patent removes the meltable mandrel and multiple CMC plies from the process. Instead, a single CMC preform with an open tip is created, and the tip is sealed using a different method (laser drilling or chemical etching) that eliminates the need for mandrels and multiple plies, thereby reducing labor and component fragility
Solution Approach 2:
Instead of building up the structure with multiple plies and removing mandrels, the patent inverts the approach by creating a single preform and then creating the internal passages through the tip after the main structure is already formed and sealed
2Reliability
If tip caps are formed from multiple CMC plies to close the open tip area, then the internal passages are sealed, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent eliminates the tip cap assembly step entirely by sealing the internal passages through the open tip using laser drilling or chemical etching methods, removing the time-consuming process of forming and assembling multiple plies
Solution Approach 2:
The mechanical assembly process of stacking and bonding multiple CMC plies is replaced with energy-based methods (laser drilling) or chemical processes (etching) that create seals through the tip material without mechanical assembly
3Reliability
If multiple CMC plies are used to form the tip cap, then the open tip area is filled and sealed, but the complexity of assembly and the risk of damage increase
Solution Approach 1:
The patent removes the complex multi-ply tip cap assembly from the process, replacing it with a simpler method of sealing internal passages through the open tip using laser drilling or chemical etching, thereby reducing assembly complexity
Solution Approach 2:
The patent changes the sealing method from mechanical assembly of multiple plies to energy-based (laser) or chemical processes that modify the material properties directly, creating seals through phase change or chemical reaction rather than mechanical bonding
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
This method reduces labor and time required for forming CMC components, minimizes the risk of damage during assembly, and eliminates the need for complex assembly and machining, resulting in a more efficient and robust manufacturing process for CMC components with sealed internal passages.
Implementation Method 1
a barrier layer is applied to at least one internal passage adjacent to the mold to form a cavity
Implementation Method 2
ceramic foam is deposited on the barrier layer and fills the cavity
Data Source
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AI summary
A method of forming a ceramic matrix composite component includes providing a formed ceramic member (90) having a cavity (70), filling at least a portion of the cavity (70) with a ceramic foam. The ceramic foam is deposited on a barrier layer (40) covering at least one internal passage (50) of the cavity (70). The method (600) includes processing the formed ceramic member (90) and ceramic foam to obtain a ceramic matrix composite component. Also provided is a method of forming a ceramic matrix composite blade and a ceramic matrix composite component.