Ceramic Matrix Composite Densification via Field Assisted Sintering
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Solution Overview
Problem
Traditional Ceramic Matrix Composite (CMC) structures face limitations in producing high-temperature materials capable of withstanding 2400°F or above, as they induce thermal and mechanical stresses, and have increased processing times due to bulk densification methods like Chemical Vapor Infiltration and Melt Infiltration, which are exacerbated by preform thickness.
Innovation Solution
The use of Field Assisted Sintering Technique (FAST), Spark Plasma Sintering (SPS), or localized heating at bonding interfaces to densify nominally dense plies in CMC structures, allowing for a gradation of CMC composition from ultra-high temperature to lower temperature materials, and incorporating features like cooling channels, voids, and reinforcement layers to enhance mechanical and thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bulk densification methods (CVI, MI, PIP) are used to densify CMC preforms, then the CMC structure achieves sufficient density, but thermal stresses and mechanical stresses increase significantly, especially with thicker preforms
Solution Approach 1:
The preform is divided into multiple individual plies that are densified separately before assembly, rather than densifying the entire thick preform as one bulk structure. This segmentation reduces the diffusion distance for each ply and minimizes thermal gradients and stresses within each individual ply.
Solution Approach 2:
The invention transitions from bulk densification (3D throughout the entire preform) to surface-level densification of individual thin plies (2D surface process). Each ply is densified as a thin layer, then multiple plies are assembled and bonded, effectively moving the densification process to a different dimensional approach that reduces thermal and mechanical stresses.
2Manufacturing precision
If traditional bulk densification methods are used on thicker preforms, then complete densification is achieved, but processing time increases significantly due to longer diffusion and infiltration distances
Solution Approach 1:
The thick preform is segmented into multiple thin plies, each with reduced thickness. This segmentation reduces the diffusion and infiltration distance for each individual ply, allowing faster densification processing while still achieving complete densification of the overall structure through assembly of multiple densely-packed plies.
Solution Approach 2:
Individual plies are densified separately before assembly into the final preform structure. This preliminary densification of thin plies is more efficient than bulk densification, and the subsequent assembly and bonding of pre-densified plies completes the process faster than attempting to densify the entire thick structure at once.
3Manufacturing precision
If traditional bulk densification is used, then the CMC structure achieves adequate density, but the ability to produce ultra-high temperature CMC structures (2400°F or above) is limited
Solution Approach 1:
The structure is segmented into multiple thin, densely-packed plies that can achieve superior density and fewer defects compared to bulk densification. This high-density microstructure enables the CMC to withstand ultra-high temperatures (2400°F or above) by reducing porosity and improving thermal stability.
Solution Approach 2:
The invention uses composite material architecture with multiple bonded plies, each contributing to the overall high-temperature performance. The interface bonding between plies creates a composite structure that enhances thermal resistance and mechanical integrity at ultra-high temperatures beyond what traditional bulk CMC can achieve.
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 approach enables the creation of CMC structures with improved mechanical and thermal properties, reduced thermal stresses, and increased efficiency in processing, allowing for the production of high-temperature components with enhanced durability and reduced production time.
Implementation Method 1
each of the plurality of the nominally dense plies are bonded by at least one of a Field Assisted Sintering Technique (FAST), a Spark Plasma Sintering (SPS), or a localized heating at a bonding interface
Implementation Method 2
each of the plurality of the nominally dense plies are bonded by at least one of a Field Assisted Sintering Technique (FAST), a Spark Plasma Sintering (SPS), or a localized heating at a bonding interface
Implementation Method 3
each of the plurality of the nominally dense plies are bonded by at least one of a Field Assisted Sintering Technique (FAST), a Spark Plasma Sintering (SPS), or a localized heating at a bonding interface
Data Source
AI summary
A turbine engine component may comprise a Ceramic Matrix Composite (CMC) structure including a plurality of nominally dense plies, wherein each of the plurality of the nominally dense plies are bonded by at least one of a Field Assisted Sintering Technique (FAST), a Spark Plasma Sintering (SPS), or a localized heating at a bonding interface. The turbine engine component may include an airfoil extending between a first platform and a second platform, wherein the airfoil, the first platform, and the second platform define the CMC structure.