Ceramic Matrix Composite Cooling Channels via Wire Embedding
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Solution Overview
Problem
Traditional machining processes struggle to effectively incorporate in-plane and curved cooling channels into ceramic matrix composite components, leading to potential fiber damage and limitations in cooling efficiency in high-temperature environments like gas turbine engines.
Innovation Solution
A method involving the insertion of wires into a fiber preform structure, followed by densification and chemical dissolution to create cooling channels without damaging the fibers, allowing for closer spacing and curved channel designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining processes are used to create cooling channels, then the component structure can be modified, but fiber damage occurs and manufacturing complexity increases
Solution Approach 1:
Wires are inserted into the fiber preform before densification to define cooling channel locations. This preliminary placement allows channels to be formed without subsequent machining that would damage fibers.
Solution Approach 2:
Wires serve as intermediary objects that temporarily occupy the space where cooling channels will eventually form. These wires are dissolved after densification, leaving clean channels without requiring mechanical removal that would harm fibers.
2Temperature
If cooling channels are added to improve cooling efficiency, then thermal performance increases, but manufacturing difficulty increases
Solution Approach 1:
The mechanical machining process is replaced with a chemical dissolution process. Instead of mechanically removing material to create channels, wires are dissolved chemically after densification, simplifying the manufacturing process.
Solution Approach 2:
The state of the wire material is changed from solid to dissolved through chemical treatment. This parameter change allows easy formation of cooling channels without complex mechanical operations.
3Reliability
If wires are inserted into preform and then dissolved, then cooling channels are formed without fiber damage, but additional process steps are required
Solution Approach 1:
The wire insertion and channel formation processes are merged into a single integrated approach. Wires are inserted, the component is densified, and then wires are dissolved to create channels, combining multiple functions into one manufacturing flow.
Solution Approach 2:
The wires are discarded after serving their purpose as channel-defining elements. Their removal through dissolution creates the final cooling channels, and the dissolved material can be recovered or disposed of.
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 enables the creation of ceramic matrix composite components with enhanced thermal properties and improved cooling efficiency, suitable for harsh environments such as gas turbine engines, without compromising the structural integrity of the fibers.
Implementation Method 1
a chemical dissolution step to remove the wires from the structure and leave behind cooling channels where the wires had been
Data Source
Figure 1
Figure 2~3
AI summary
A method (10) of forming a ceramic matrix composite component (22) with cooling channels (34) includes embedding a plurality of wires (30) into a preform structure (26), densifying the preform structure (26) with embedded wires (30), and removing the plurality of wires (30) to create a plurality of corresponding channels (34) within the densified structure.