CMC Cooling Features via Fugitive Inserts
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Solution Overview
Problem
Current ceramic matrix composite components in gas turbine engines are limited by machining techniques, which restrict the formation of complex geometric features and require material removal processes, such as drilling, resulting in linear features and inefficiencies in cooling designs.
Innovation Solution
A method involving the use of high-temperature resistant fugitive material inserts during the manufacturing process of ceramic matrix composite components, allowing for the creation of complex, non-linear cooling features through pyrolysis and melt infiltration, with mechanical or chemical removal of the inserts to form in-situ cavities, enabling more efficient cooling and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If machining techniques are used to form cooling features in ceramic matrix composite components, then the manufacturing process is simple and straightforward, but the geometric complexity of cooling features is limited to linear shapes
Solution Approach 1:
The patent applies preliminary action by placing fugitive material inserts into the preform during the molding process, before the final component is completed. These inserts are positioned in advance to define the desired complex cooling feature geometry, which is then formed during pyrolysis and infiltration. This eliminates the need for subsequent machining operations and enables geometric complexity that cannot be achieved through traditional drilling or machining methods.
Solution Approach 2:
The patent uses fugitive material inserts as intermediaries to transfer the desired cooling feature geometry into the final component. These inserts serve as temporary mediators that define the cavity shape during manufacturing, then are removed after serving their purpose. This intermediary approach enables complex non-linear cooling features to be formed without requiring complex machining operations.
2Productivity
If machining processes are used to create cooling features, then the component structure remains intact, but material removal is required which increases manufacturing time and reduces design flexibility
Solution Approach 1:
The patent applies the taking out principle by extracting the harmful material removal step from the manufacturing process. Instead of machining away material to create cooling features, the method builds the features directly into the component during molding by using fugitive inserts that are later removed. This eliminates material loss and reduces manufacturing time by forming features additively rather than subtractively.
Solution Approach 2:
The patent changes the manufacturing parameter from subtractive machining to additive forming. By transitioning from mechanical removal of material to in-situ formation of cooling features during pyrolysis and infiltration, the process eliminates material loss and significantly improves productivity. The parameter change enables complex geometries to be formed without the time-consuming machining operations previously required.
3Adaptability or versatility
If traditional molding techniques are used without inserts, then the manufacturing process is simpler, but complex non-linear cooling features cannot be formed
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into distinct stages: preform creation with inserted fugitive materials, pyrolysis, and infiltration. This segmentation allows complex cooling features to be formed in the pyrolysis stage through the removal of fugitive inserts, while keeping the preform creation and infiltration stages relatively simple. The segmentation enables design flexibility without overwhelming process complexity.
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 formation of complex, non-linear cooling features that enhance thermal management and reduce material removal steps, improving the efficiency and design capabilities of ceramic matrix composite components in gas turbine engines.
Implementation Method 1
through pyrolysis and melt infiltration
Implementation Method 2
through pyrolysis and melt infiltration
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Methods and materials for forming in-situ features in a CMC component (200) are described. The method of forming a ceramic matrix composite component with cooling features, comprises forming a preform tape (120), laying up (122) said preform tape to a desired shape, placing a high-temperature resistant fugitive material insert (30) of preselected geometry in the preform tape of the desired shape, compacting (134) the preform tape of the desired shape, burning out (138) the preform tape of the desired shape, melt infiltrating (140) the desired shape, removing the high-temperature resistant insert to form the cooling features during one of the burning out or the melt infiltrating or following the burning out or the melt infiltrating.