CMC Reinforcement Structure via Focused-Energy CVD Deposition
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Solution Overview
Problem
Existing additive manufacturing techniques for ceramic matrix composites face challenges in achieving complex geometries and efficient deposition of refractory materials, particularly due to the high cost and limitations of woven fiber reinforcements.
Innovation Solution
A method using chemical vapor deposition assisted by focused energy radiation to form a reinforcement with interconnected elements and an interstitial volume of tortuous shape, allowing for the deposition of a wide variety of materials, including ceramics, without fiber weaving, and optionally incorporating a matrix and interphase during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If woven fibrous reinforcements are used for CMC parts, then mechanical properties and high temperature resistance are achieved, but the cost increases and geometric flexibility is limited
Solution Approach 1:
The patent replaces the mechanical weaving process with a chemical vapor deposition process assisted by focused energy radiation. Instead of physically weaving refractory fibers into complex patterns, the invention uses localized heating to deposit and transform precursors into reinforcement structures directly, eliminating the need for mechanical textile operations while maintaining structural integrity and mechanical properties
Solution Approach 2:
The invention changes the physical and chemical parameters of the deposition process by using focused energy radiation to locally heat and transform precursors. This allows control over the reinforcement structure formation through parameter adjustment (energy density, deposition rate, temperature profiles) rather than through mechanical weaving constraints, enabling both cost reduction and geometric flexibility
2Strength
If woven fibrous reinforcements are used, then structural integrity is maintained, but the ability to produce complex geometries is limited
Solution Approach 1:
The patent replaces the mechanical weaving process with a chemical vapor deposition process assisted by focused energy radiation. Instead of physically weaving refractory fibers into complex patterns, the invention uses localized heating to deposit and transform precursors into reinforcement structures directly, eliminating the need for mechanical textile operations while maintaining structural integrity and mechanical properties
Solution Approach 2:
The invention transitions from two-dimensional woven textile structures to three-dimensional reinforcement architectures that can be directly deposited into complex geometries. The focused energy radiation enables deposition in multiple directions and orientations, creating tortuous interstitial volumes and complex reinforcement patterns that cannot be achieved with conventional planar weaving
3Ease of manufacture
If conventional additive manufacturing techniques are used for ceramic deposition, then material deposition is attempted, but satisfactory results for refractory materials are not achieved
Solution Approach 1:
The invention changes the physical and chemical parameters of the deposition process by using focused energy radiation to locally heat and transform precursors. This allows control over the reinforcement structure formation through parameter adjustment (energy density, deposition rate, temperature profiles) rather than through mechanical weaving constraints, enabling both cost reduction and geometric flexibility
Solution Approach 2:
The patent introduces focused energy radiation as an intermediary between the precursor materials and the final reinforcement structure. This intermediary enables precise local heating and transformation of precursors into refractory materials, bridging the gap between conventional additive manufacturing capabilities and the requirements for high-quality ceramic matrix composite deposition
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
Enables the production of structures with optimized reinforcement properties and complex geometries, overcoming limitations of woven textures and providing flexibility in material deposition, suitable for applications like turbomachine parts.
Implementation Method 1
the formation of a reinforcement by chemical vapor deposition assisted by focused energy radiation
Implementation Method 2
chemical vapor deposition in which there is transformation of one or several precursors under the effect of a localized and punctual heating produced by the focused energy radiation
Data Source
AI summary
A method for manufacturing a structure by an additive manufacturing technique implementing a chemical vapor deposition assisted by focused energy radiation, includes the formation of a reinforcement which comprises a plurality of interconnected reinforcing elements made of ceramic or carbon, which define therebetween an interstitial volume having a tortuous shape along the deposition axis.