Composite Component Densification via Intersecting Fluid Pathways
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Solution Overview
Problem
Existing densification processes for composite components, such as chemical vapor infiltration (CVI) and melt infiltration (MI), often result in incomplete densification due to 'choking off' of infiltration pathways, preventing effective penetration of densification fluids into inner portions of the component, especially in thicker materials.
Innovation Solution
The method involves creating fluid pathways in the composite component's ply layup that are dimensionally larger than typical pores, allowing for deeper penetration of densification fluids by intersecting pathways that prevent premature filling and ensure complete infiltration, thereby enhancing densification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional densification processes (CVI/MI) are used, then surface densification is achieved, but inner portions of the component remain under-densified due to pathway choking
Solution Approach 1:
The invention segments the continuous infiltration pathway into multiple discrete channels by forming separate through-thickness channels at different lateral positions. This segmentation prevents the choking effect that occurs in conventional single-pathway approaches, allowing densification fluid to reach inner portions of thick components through multiple independent routes.
Solution Approach 2:
The invention transitions from a single-dimensional infiltration approach to a multi-dimensional network of channels. By creating channels at various lateral positions that intersect and connect, the system adds spatial complexity that enables fluid to navigate through the thickness of the component via multiple routes, preventing pathway blockage.
2Speed
If fluid pathways are made larger to enable deeper penetration, then infiltration depth improves, but pathway stability and structural integrity may be compromised
Solution Approach 1:
Instead of creating one large pathway, the invention divides the infiltration network into multiple smaller channels distributed at different lateral positions. Each channel maintains sufficient stability while collectively providing deep penetration capability through their combined network.
Solution Approach 2:
The channels are formed to intersect and connect with one another, creating a nested or interconnected network structure. This nesting allows the fluid to transition between channels at different depths and lateral positions, maintaining pathway stability while achieving deep infiltration through the component thickness.
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 approach leads to more complete densification, improved mechanical performance, and the ability to produce thicker composite components with comparable properties to thinner parts, without the need for hybrid cooling structures, thus expanding the application scope for high-temperature gas turbine engine components.
Implementation Method 1
allowing for deeper penetration of densification fluids by intersecting pathways that prevent premature filling and ensure complete infiltration
Data Source
AI summary
Composite components and methods of densifying composite components are provided. For example, a composite component includes a first ply having a first plurality of unidirectional arrays of fiber tows extending in a first direction and a second ply having a second plurality of unidirectional arrays of fiber tows extending in a second direction. A first fluid pathway is defined in the first ply that has a first length greater than a first width, and a second fluid pathway is defined in the second ply that has a second length greater than a second width. The first and second fluid pathways may improve densification of the composite component by improving penetration of a densification fluid in the composite component.