Multi-stage consolidation for ceramic matrix composite prepreg
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Solution Overview
Problem
The design and manufacture of high-temperature-resistant composite materials for gas turbine engine components, such as vanes and blades, face challenges due to the required geometry and strength, which existing methods struggle to achieve effectively.
Innovation Solution
A method involving a layup process on a layup tool, followed by preliminary and final consolidation stages using specific consumables, to partially and fully cure ceramic matrix composite components, ensuring high-temperature resistance and minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing manufacturing methods are used for ceramic matrix composite components, then the production process is simpler, but the high-temperature resistance and strength of the components are insufficient
Solution Approach 1:
The consolidation process is divided into multiple stages: initial consolidation at lower temperature to remove excess resin and achieve partial cure, followed by final consolidation at higher temperature to achieve full cure and desired properties. This segmentation allows each stage to be optimized independently, achieving high-temperature resistance without requiring a single complex high-temperature process
Solution Approach 2:
The initial consolidation stage performs preliminary curing and resin removal before the final consolidation stage. This preliminary action prepares the composite structure to better withstand the subsequent high-temperature final consolidation, enabling the achievement of high-temperature resistance through a staged approach rather than a single complex process
2Reliability
If existing manufacturing methods are used for ceramic matrix composite components, then the manufacturing process is faster, but the defects in the components increase
Solution Approach 1:
The manufacturing process is segmented into initial consolidation (removing excess resin and achieving partial cure) and final consolidation (achieving full cure). This segmentation allows excess resin to be removed before final curing, significantly reducing voids and defects in the final product, thereby improving component quality and reliability
Solution Approach 2:
The initial consolidation stage performs preliminary resin removal and partial curing before the final consolidation stage. This preliminary action eliminates excess resin that would otherwise create defects during final curing, ensuring higher component quality without requiring rework or additional defect correction steps
3Manufacturing precision
If single-stage consolidation is used, then the manufacturing process is simpler, but the geometry and strength requirements are not met
Solution Approach 1:
The consolidation process is segmented into initial consolidation at lower temperature to establish basic geometry and remove excess resin, followed by final consolidation at higher temperature to achieve precise final geometry and desired strength properties. This segmentation enables progressive refinement of geometry and properties
Solution Approach 2:
The consolidation process utilizes parameter changes by transitioning from lower temperature and pressure in the initial stage to higher temperature and pressure in the final stage. This parameter progression allows the composite to first achieve basic consolidation and geometry, then refine to precise dimensional tolerances and optimal mechanical properties
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 enables the production of ceramic matrix composite components with improved high-temperature resistance and reduced defects, effectively addressing the challenges of geometry and strength in gas turbine engine components.
Implementation Method 1
applying a vacuum pressure to withdrawn air between the set of preliminary consolidation consumables and the layup
Implementation Method 2
heating the layup to a first predetermined temperature for a predetermined preliminary consolidation period to partially cure the layup
Data Source
AI summary
A method used for forming ceramic matrix composite components includes several steps. The method comprises arranging a layup of a predetermined number of prepreg ceramic plies on a layup too and a plurality of different stages to debulk and consolidate the layup.