CMC Ply Assembly with Fiber-Free Matrix for Melt Infiltration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ceramic matrix composite (CMC) components, particularly those with thick solid sections, face challenges in densification due to incomplete melt infiltration, leading to production failures and inefficiencies in gas turbine components.
Innovation Solution
Incorporating a matrix ply interspersed amongst CMC plies, which is free of ceramic fibers, allows for more complete infusion and densification of a melt infiltration agent, promoting thorough infiltration and densification of the CMC article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CMC components with thick solid sections are densified using conventional methods, then production time and cost are reduced, but melt infiltration is insufficient leading to production failures
Solution Approach 1:
The invention segments the CMC component structure by introducing separate matrix plies that are free of ceramic fibers. These matrix plies act as dedicated channels for melt infiltration, allowing the melt to penetrate more effectively through thick solid sections without being blocked by fiber networks, thereby resolving the contradiction between production efficiency and densification completeness.
Solution Approach 2:
The matrix plies serve as intermediary elements between the external melt source and the internal CMC structure. By providing fiber-free pathways, these matrix plies mediate the infiltration process, enabling complete densification of thick sections while maintaining production efficiency.
2Manufacturing precision
If CMC components are densified to ensure complete melt infiltration, then quality and durability are improved, but production time and complexity increase
Solution Approach 1:
By segmenting the ply assembly into CMC plies and separate matrix plies, the invention creates dedicated infiltration channels that simplify the densification process. The matrix plies are strategically positioned to guide melt flow, ensuring complete infiltration without requiring overly complex processing equipment or procedures.
Solution Approach 2:
The invention applies local quality by making specific regions (matrix plies) fiber-free to optimize their function as infiltration pathways. This localized structural modification ensures complete melt infiltration where needed while maintaining the overall CMC structure, balancing manufacturing precision with structural complexity.
3Reliability
If matrix plies free of ceramic fibers are interspersed amongst CMC plies, then melt infiltration completeness is improved, but structural complexity of the ply assembly increases
Solution Approach 1:
The ply assembly is segmented into alternating CMC plies and matrix plies, creating a structured pattern that facilitates melt infiltration. This segmentation provides clear, organized pathways for the melt to travel through thick sections, improving densification completeness while maintaining a manageable ply stack arrangement.
Solution Approach 2:
The invention merges the structural function of CMC plies with the infiltration function of matrix plies into a unified ply stack. By combining these different ply types in a coordinated arrangement, the structure achieves both mechanical integrity and complete densification without excessive 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 enhances the densification process, increasing the completeness of melt infiltration, improving the quality, durability, and strength of CMC articles, while reducing costs and production failures.
Implementation Method 1
The melt infiltration agent infuses more completely through the at least one matrix ply than through the plurality of CMC plies
Implementation Method 2
The CMC ply assembly is densified with the melt infiltration agent to form the CMC article
Data Source
AI summary
A CMC ply assembly is disclosed including at least one matrix ply interspersed amongst a plurality of CMC plies. Each of the plurality of CMC plies includes a first matrix and a plurality of ceramic fibers. The at least one matrix ply includes a second matrix and is essentially free of ceramic fibers. The plurality of CMC plies and the at least one matrix ply are arranged in an undensified ply stack having an article conformation. A CMC article is disclosed including a plurality of densified CMC plies and at least one densified matrix ply interspersed amongst the plurality of densified CMC plies. A method for forming the CMC article is disclosed including forming, carburizing, infusing a melt infiltration agent into, and densifying the CMC ply assembly. The melt infiltration agent infuses more completely through the at least one matrix ply than through the plurality of CMC plies.