CMC Article Densification via Entrained Melt Infiltration
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Solution Overview
Problem
Ceramic matrix composite (CMC) components with thick solid sections face challenges in full densification due to insufficient melt infiltration, which affects their performance and durability in high-temperature applications like gas turbines.
Innovation Solution
A method for forming CMC articles involves creating a precursor ply assembly with a melt infiltration agent, which is infused and densified to enhance infiltration and densification, particularly using a combination of ceramic fibers and a matrix precursor, with the agent distributed homogeneously or heterogeneously to achieve complete densification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional CMC components with thick solid sections are formed without entrained melt infiltration agent, then the manufacturing process is simpler, but the densification is insufficient and performance is compromised
Solution Approach 1:
The melt infiltration agent is entrained within the CMC precursor plies before carbonization and densification. This preliminary placement ensures that the agent is already positioned within the thick solid sections, enabling complete infiltration and densification during subsequent processing without requiring complex external delivery systems.
Solution Approach 2:
The melt infiltration agent acts as an intermediary substance that facilitates complete densification of thick CMC sections. It is incorporated into the precursor plies and melts during processing to fill voids and pores, enabling thorough infiltration that would otherwise be impossible with conventional methods.
2Manufacturing precision
If external melt infiltration methods are used to achieve complete densification of thick sections, then densification can be improved, but the process complexity and cost increase
Solution Approach 1:
The CMC component itself contains the means for its own complete densification through the entrained melt infiltration agent. During processing, the agent melts and infiltrates the thick solid sections from within, eliminating the need for complex external infiltration equipment or multi-step processes.
Solution Approach 2:
The manufacturing process merges the placement of CMC precursors with the inclusion of melt infiltration agent into a single step. The agent is entrained within the precursor plies during layup, combining material placement and infiltration agent delivery into one integrated process, thereby simplifying overall manufacturing.
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 results in increased densification, improved strength, stiffness, and durability of CMC articles, reducing material property variations and enhancing process efficiency, with densification levels reaching up to 90% compared to 66% without the agent supply.
Implementation Method 1
The CMC precursor ply assembly is carbonized
Implementation Method 2
the melt infiltration agent from the entrained agent supply is infused into the plurality of CMC precursor plies
Data Source
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AI summary
A method for forming a CMC article (200) is disclosed, including forming a CMC precursor ply assembly (100). Forming the CMC precursor ply assembly (100) includes laying up a plurality of CMC precursor plies (102) and entraining a melt infiltration agent (104) to form an entrained agent supply (106). Each of the plurality of CMC precursor plies (102) includes a first matrix precursor (108) and a plurality of ceramic fibers (110). The plurality of CMC precursor plies (102) and the entrained agent supply (106) are arranged to form the CMC precursor ply assembly (100), which includes an article conformation (112). The method further includes carbonizing the CMC precursor ply assembly (100), infusing the melt infiltration agent (104) from the entrained agent supply (106) into the plurality of CMC precursor plies (102), and densifying the CMC precursor ply assembly (100) with the melt infiltration agent (104) to form the CMC article (200).