Ceramic Matrix Composite Cavity Cooling via Capillary Infiltration
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Solution Overview
Problem
Current methods for forming ceramic matrix composite (CMC) components with internal cavities for gas turbines are complex and costly, requiring expensive tooling and potential residual sacrificial material, which can lead to thermal gradients and stress, limiting cooling efficiency and increasing life cycle costs.
Innovation Solution
A process involving the positioning of ceramic matrix composite plies to form cavities with a terminal diameter small enough for densifying material infiltration, allowing for efficient cooling without the need for expensive tooling and reducing residual material risks, by using capillary forces to fill and solidify matrix material within the cavities during densification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If removable and expendable tooling is used to form internal cooling channels in CMC components, then cooling efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the cooling channel formation process from complex tooling requirements by using a simplified mandrel system that is easily removed after densification, eliminating the need for complicated removable and expendable tooling while maintaining effective internal cooling channels
Solution Approach 2:
Instead of forming cooling channels through complex tooling intervention, the invention inverts the approach by using a mandrel that defines the negative space, which is then removed after densification to leave the desired cooling channels, simplifying the overall manufacturing system
2Shape
If mandrel materials are melted out through burn-out cycle, then cavity formation is achieved, but residual sacrificial material remains causing thermal gradients and stress
Solution Approach 1:
The invention converts the potential harm of residual material by using a mandrel material and densifying material combination where the densifying material completely replaces the mandrel material through capillary infiltration, transforming the removal process from melting out (which leaves residues) to complete infiltration and replacement, eliminating thermal gradients and stress
Solution Approach 2:
The invention changes the physical and chemical parameters of the densifying material to ensure complete infiltration and replacement of mandrel material, using capillary forces and controlled densification conditions to achieve complete material substitution without residues, thereby eliminating thermal gradients
3Manufacturing precision
If multiple processing steps with heat application are used for CMC fabrication, then material densification is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The invention merges the densification process with the mandrel removal process into a single integrated step, where the densifying material infiltrates and replaces the mandrel material simultaneously, eliminating the need for separate burn-out cycles and reducing both manufacturing cost and process complexity while maintaining densification quality
4Strength
If conventional superalloy materials are used for turbine blades, then structural strength is maintained, but weight and cooling requirements increase
Solution Approach 1:
The invention uses ceramic matrix composite materials for turbine blades, which provide comparable or superior structural strength to conventional superalloys while significantly reducing weight and cooling requirements, enabling more efficient turbine component design
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 enables near-wall cooling, reduces thermal gradients, lowers cooling demand, and extends component life while reducing costs and design complexity, allowing for more efficient and flexible cooling of hot-gas-path hardware in gas turbines.
Implementation Method 1
At least a portion of the cavity includes a terminal diameter sufficiently small to permit infiltration of a densifying material... The plurality of ceramic matrix composite plies are densified to form a densified body. The densifying results in the portion of the cavity including the terminal diameter being filled with densifying material
Data Source
AI summary
A process of producing a ceramic matrix composite component. The process includes positioning a plurality of ceramic matrix composite plies on top of one another and forming a cavity therein. At least a portion of the cavity includes a terminal diameter sufficiently small to permit infiltration of a densifying material. The plurality of ceramic matrix composite plies are densified to form a densified body. The densifying results in the portion of the cavity including the terminal diameter being filled with densifying material and the cavity is present in the densified body. A ceramic matrix composite having cavities therein is also disclosed.