CMC Repair Joining Plies for Delamination-Resistant Components

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Solution Overview

Problem

CMC components in gas turbine engines are prone to damage due to abrasion and impact, leading to structural weaknesses and the need for effective repair methods that maintain laminar organization and structural integrity.

Innovation Solution

The use of joining plies with off-plane fiber directions to repair CMC components, which are folded or arranged in a ply stack to improve infiltration and retention, and subsequently fused using processes like melt infiltration or brazing to form a unified structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional repair methods are used on CMC components, then the repair process is simpler, but the structural strength and durability are reduced due to delamination and poor load distribution

Engineering Contradiction:

Improvestructural strengthVSAvoidrepair process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent uses composite repair plies made of CMC materials with fiber directions oriented off-plane relative to the component plies. This composite structure combines the repair plies with the damaged CMC component through infiltration processes, creating a unified structure that restores and enhances structural strength while preventing delamination.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces a new dimension to the repair approach by orienting the fiber directions of repair plies off-plane (at angles between 30-60 degrees) relative to the component plies. This three-dimensional fiber orientation improves load distribution in multiple directions and prevents delamination, rather than simply layering plies in the same plane as conventional repairs.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If joining plies with off-plane fiber directions are used, then delamination is reduced and load distribution is improved, but the repair process becomes more complex

Engineering Contradiction:

Improvelaminar organization integrityVSAvoidrepair ease

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent changes the critical parameter of fiber orientation from the conventional in-plane alignment to off-plane angles between 30-60 degrees. This parameter change fundamentally improves the mechanical interlocking between repair plies and component plies, preventing delamination and enhancing reliability, though it requires more complex positioning and alignment during the repair process.

Inventive Principle:

Principle #35Parameter changes

3Strength

If multiple joining plies are stacked and fused, then the repaired component achieves unified structure and enhanced strength, but the manufacturing process becomes more complex

Engineering Contradiction:

Improverepaired component strengthVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent requires preliminary arrangement of multiple joining plies in a specific stack configuration with predetermined off-plane fiber orientations before the infiltration process. This preliminary positioning ensures proper load distribution and structural integrity, but adds complexity to the manufacturing process as each ply must be carefully placed and secured before fusion.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes phase transitions during the infiltration process, where molten infiltration material transitions from liquid to solid state, fusing the multiple joining plies together with the component plies. This phase change creates a unified, monolithic structure that enhances strength, though it requires precise control of temperature and timing in the manufacturing process.

Inventive Principle:

Principle #36Phase transitions

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

Enhances the structural strength and durability of repaired CMC components by reducing delamination and improving load distribution, while maintaining the integrity of the component's laminar organization.

Implementation Method 1

heating the CMC component to fuse the plurality of joining plies to the repair area

Methodology Applied

Scientific EffectMelt infiltration:

Implementation Method 2

heating the CMC component to fuse the plurality of joining plies to the repair area, including, but not limited to, infiltration processes, sintering, brazing, or the like

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS12577174B2Ceramic matrix composite component repairing and joining

Publication Date: 2026.03.17 GENERAL ELECTRIC CO

AI summary

A method for joining a ceramic matrix composite (CMC) component includes placing a plurality of joining plies onto a specified area such that a respective fiber direction of each of the plurality of joining plies is off-plane to a fiber direction of one or more composite plies of the specified area. The respective fiber direction of each of the plurality of joining plies differs from the respective fiber direction of each adjacent one of the plurality of joining plies.