Oxide-oxide CMC Edge Repair via Metallic Diffusion Bonding
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Solution Overview
Problem
Oxide-oxide ceramic matrix composites (CMCs) used in gas turbine engines face challenges such as low mechanical capability and interfacing issues with metallic geometry, leading to detachment of fiber layers and harsh wear rates, especially at trailing edges and attachment features, which affect their structural integrity and lifespan.
Innovation Solution
Applying a metallic material at the edges or damaged areas of oxide-oxide CMCs, where it diffuses into the composite upon heating, forming a bond with the ceramic matrix and reinforcing the structure, either as a solid layer, liquid, or powder, to enhance mechanical properties and improve compatibility with metallic hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If oxide-oxide CMCs are used in gas turbine engines to reduce weight and improve thermal properties, then weight reduction and thermal performance are improved, but mechanical capability and structural integrity deteriorate
Solution Approach 1:
The patent applies composite materials by combining oxide-oxide CMC with metallic reinforcement materials (such as nickel-based superalloys) to create a hybrid structure. The CMC provides weight reduction and thermal properties, while the metallic phase embedded within or on the CMC surface provides enhanced mechanical strength and structural integrity, resolving the contradiction between weight reduction and mechanical capability
Solution Approach 2:
The patent applies local quality by selectively placing metallic reinforcement materials at specific locations within or on the CMC structure, such as at fiber layer interfaces or at stress-concentration areas. This localized metallic reinforcement provides mechanical strength where needed while maintaining the overall lightweight CMC structure in other areas
2Temperature
If oxide-oxide CMCs are used to achieve low weight and excellent thermal properties, then thermal performance is improved, but interfacing with metallic geometry deteriorates leading to detachment
Solution Approach 1:
The patent creates a composite structure where metallic phases are integrated within the CMC matrix, providing compatible interfaces for metallic hardware attachment. The metallic inclusions or reinforcement phases serve as anchoring points for metallic geometry, enabling reliable interfacing while maintaining the thermal performance of the CMC structure
Solution Approach 2:
The metallic reinforcement materials act as intermediaries between the CMC substrate and metallic hardware components. These metallic phases provide a chemically and mechanically compatible interface that facilitates reliable bonding and attachment, resolving the interfacing issues between oxide-oxide CMC and metallic geometry
3Weight of moving object
If oxide-oxide CMCs are used for structural applications, then weight reduction is achieved, but wear resistance deteriorates at trailing edges and attachment features
Solution Approach 1:
The patent employs composite materials with metallic reinforcement phases that provide superior wear resistance compared to pure CMC. The metallic components, particularly nickel-based superalloys, offer enhanced hardness and wear resistance at critical areas like trailing edges and attachment features, while the overall composite structure maintains the lightweight advantage of CMC
Solution Approach 2:
The patent applies local quality by concentrating wear-resistant metallic phases at specific locations prone to wear, such as trailing edges and attachment features. This localized reinforcement provides enhanced wear resistance where needed while maintaining weight reduction in other portions of the component
4Strength
If fiber layers are used in oxide-oxide CMCs to provide structural support, then structural integrity is improved, but detachment of fiber layers occurs at edges
Solution Approach 1:
The patent uses composite materials where metallic reinforcement phases are positioned at fiber layer interfaces and edges. These metallic inclusions act as bonding agents that mechanically interlock with the fiber layers, preventing detachment while maintaining the structural integrity provided by the fiber architecture
Solution Approach 2:
The metallic reinforcement materials serve as intermediaries between adjacent fiber layers, particularly at edge regions where detachment occurs. These metallic phases provide chemical and mechanical bonding that secures the fiber layers to each other, preventing delamination while preserving the load-bearing capacity of the fiber structure
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 effectively reinforces the oxide-oxide CMCs by improving their mechanical strength, reducing dynamic strains, and extending the lifespan of components like mixers by forming a strong, uniform diffusion bond, thereby enhancing the structural integrity and reducing weight.
Implementation Method 1
heating the metallic material to diffuse the metal material into the oxide-oxide CMC substrate at the edge
Data Source
AI summary
In some examples, techniques of repairing and/or reinforcing oxide-oxide ceramic matrix composite (CMC) materials using a metallic material. In one example, a method including applying a metallic material at an edge of an oxide-oxide CMC substrate; and heating the metallic material to diffuse the metal material into the oxide-oxide CMC substrate at the edge. In another example, a method including applying a metallic material onto a damaged area of the oxide-oxide CMC; applying a reinforcing phase material onto the damaged area of the oxide-oxide CMC; and heating the metallic material to diffuse the metallic material into the oxide-oxide CMC and attach the reinforcing phase material to the damaged area of the oxide-oxide CMC.