Localized particle additions to reduce defects in ceramic matrix composites caused by complex geometry preforming
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Solution Overview
Problem
Conventional layup techniques in ceramic matrix composites result in distortions and reduced fiber regions due to complex geometries, leading to non-uniform density and compromised performance of turbine engine components.
Innovation Solution
A method involving the selective application of ceramic particles to reduced fiber regions in a fiber preform, avoiding non-reduced regions, followed by densification processes like CVI or CVD to enhance uniformity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional layup techniques are used to form fiber preforms with complex geometries, then the component can achieve the desired shape, but fiber distortion and reduced fiber regions occur leading to non-uniform density
Solution Approach 1:
The patent applies different areal weights of ceramic particles to different regions of the fiber preform. Specifically, reduced areal weight applications are applied to convex regions while normal areal weight applications are applied to concave regions, creating local quality variations that compensate for geometry-induced fiber distortion and achieve uniform final density throughout the component.
2Shape
If conventional layup techniques are used for complex geometries, then the component shape is achieved, but defects are introduced that compromise performance
Solution Approach 1:
The patent performs preliminary action by applying ceramic particles to the fiber preform before matrix formation. This pre-application of particles to reduced fiber regions prevents defects during subsequent densification processes, ensuring uniform density and reliable component performance in the final product.
3Ease of manufacture
If uniform ceramic particle application is applied to the entire preform, then the application process is simple, but non-reduced fiber regions receive excessive particles leading to non-uniform density
Solution Approach 1:
The patent implements local quality by differentiating particle application strategies for different regions. Reduced areal weight applications are targeted at convex regions with reduced fiber content, while normal areal weight applications are applied to concave regions with adequate fiber content, achieving uniform final density without excessive particle accumulation.
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 improves the uniform density and mechanical properties of ceramic matrix composites, ensuring high performance and durability in harsh environments like gas turbine engines.
Implementation Method 1
selectively applying ceramic particles to the reduced fiber region
Implementation Method 2
subsequently densifying the preform
Implementation Method 3
densifying the preform
Data Source
AI summary
A method of forming a ceramic matrix composite component includes forming a fiber preform, the fiber preform including a plurality of ceramic fiber plies, a non-reduced fiber region having an areal weight, and a reduced fiber region characterized by a reduced areal weight less than the areal weight of the non-reduced fiber region by at least 5 percent. The method further includes selectively applying ceramic particles to the reduced fiber region in such manner as to avoid applying the ceramic particles to the non-reduced fiber region, and subsequently densifying the preform.