Composite Barrier Segment for Re-Infiltration Silicon Control
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Solution Overview
Problem
During the infiltration of green, uninfiltrated material into a previously infiltrated composite component, constituents such as silicon can migrate from the original CMC component to the new material, weakening the original component and causing voids, cracks, or other undesirable elements in the resulting composite.
Innovation Solution
Incorporating a barrier segment with lower permeability between the infiltrated and green segments to slow or prevent the migration of constituents by creating a drop in permeability at their interface, ensuring silicon flow originates from an external source during the infiltration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If green, uninfiltrated material is laid up with the original CMC component and subjected to infiltration, then porosity is reduced and the green material is strengthened, but free silicon or other constituents in the original CMC component migrate from the original component to the green material, weakening the original CMC component
Solution Approach 1:
A barrier layer is introduced as an intermediary between the green material and the original infiltrated CMC component. This barrier layer prevents direct contact and constituent migration while still allowing the infiltration process to proceed effectively into the green material, thus reducing porosity without causing silicon loss from the original component.
Solution Approach 2:
The interface region between the green material and the original CMC component is segmented by introducing a distinct barrier layer. This segmentation isolates the two materials, preventing constituent migration while maintaining the structural integrity and functionality of both regions during the infiltration process.
2Strength
If green, uninfiltrated material is laid up with the original CMC component and subjected to infiltration, then the green material is strengthened, but voids or cracks may form in the resulting composite due to constituent migration
Solution Approach 1:
The barrier layer serves as a protective intermediary that prevents constituent migration which would otherwise create voids or cracks. By blocking the migration path, the barrier layer ensures that the green material can be fully infiltrated and strengthened without compromising the overall composite integrity.
Solution Approach 2:
The barrier layer is placed in advance at the interface between the green material and the original CMC component to prevent harmful constituent migration before it can occur. This preemptive measure cushions against the formation of voids or cracks during the infiltration process.
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
Prevents the loss of silicon and other constituents from the original component to the new material, maintaining the integrity of the composite by reducing voids and cracks, thus enhancing the strength and durability of the final composite component.
Implementation Method 1
the barrier segment has a barrier segment permeability that is lower than an infiltrated segment permeability of the infiltrated segment, a green segment permeability of the green segment, or both the infiltrated segment permeability and the green segment permeability
Data Source
AI summary
A composite component may include an infiltrated segment infiltrated with a molten material during a prior infiltration process, a green segment that is uninfiltrated, and a barrier segment having a microstructure different from the infiltrated segment, the green segment, or both. The microstructure of the barrier segment may be configured to slow a flow of material between the infiltrated segment and the green segment during a subsequent infiltration process.