CMC Surface Roughness Reduction via Filler Matrix Infiltration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Implementing ceramic matrix composites (CMCs) in gas turbine engine airfoils is challenging due to surface roughness issues that affect aerothermal, aerodynamic, and durability performance.

Innovation Solution

A method involving the formation of ceramic matrix composite components by infiltrating ceramic-based reinforcements with a ceramic-based matrix, applying filler particles to fill gaps between the reinforcements, and infiltrating these particles with a filler matrix to provide mechanical, thermal, and environmental protection, while maintaining the underlying material's characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If CMC components are used in gas turbine engine airfoils, then high temperature resistance is improved, but surface roughness increases affecting aerothermal and aerodynamic performance

Engineering Contradiction:

Improvehigh temperature resistanceVSAvoidsurface roughness

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The patent applies composite materials by combining CMC components with a filler matrix coating. The coating layer is applied over the CMC surface, creating a composite structure where the CMC provides high temperature resistance while the filler matrix coating provides a smooth surface finish, thereby resolving the contradiction between temperature resistance and surface roughness

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by treating only the surface layer of the CMC component with a filler matrix coating. The bulk CMC material maintains its high temperature resistance properties while the surface layer is modified to provide smooth aerodynamic characteristics, allowing different regions of the component to have different functional properties

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If filler particles are applied to fill gaps between ceramic-based reinforcements, then surface roughness is reduced, but device complexity increases

Engineering Contradiction:

Improvesurface roughnessVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single coating process. The filler matrix coating simultaneously fills surface gaps to reduce roughness and provides aerothermal protection, combining surface finishing and protective coating operations into one integrated process, thereby reducing overall device complexity despite the added coating step

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If filler matrix is applied over ceramic-based reinforcements and matrix, then aerothermal and aerodynamic performance is improved, but manufacturing cost increases

Engineering Contradiction:

Improveaerothermal and aerodynamic performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent utilizes parameter changes by controlling the composition, thickness, and application parameters of the filler matrix coating. By optimizing these parameters, the coating provides enhanced aerothermal and aerodynamic performance while minimizing material usage and processing requirements, thereby balancing performance improvement with manufacturing cost

Inventive Principle:

Principle #35Parameter changes

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 method significantly reduces surface roughness, enhancing the aerothermal, aerodynamic, and durability performance of CMC components without altering the underlying material, thereby improving the functionality of gas turbine engine components.

Implementation Method 1

infiltrating the filler particles with a filler matrix

Methodology Applied

Scientific EffectInfiltration:

Implementation Method 2

the method includes the step of evaporating the liquid carrier after the applying step

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20230159397A1Ceramic matrix composite article and method of making the same

Publication Date: 2023.05.25 RTX CORP

AI summary

A method of making a ceramic matrix composite component includes forming a ceramic matrix composite component by infiltrating an array of ceramic-based reinforcements with a ceramic-based matrix, applying filler particles to a surface of the ceramic matrix composite component such that the filler particles fill in gaps between adjacent ones of the ceramic-based reinforcements, and infiltrating the filler particles with a filler matrix. A ceramic matrix composite component is also disclosed.