Composite Panel Infiltration Through Coarse-Pore Cores
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Solution Overview
Problem
Existing methods for preparing ceramic matrix composites (CMCs) face challenges in infiltrating thick preforms due to premature closure of infiltration pathways, leading to incomplete infiltration and defective parts, especially in larger structures where the infiltrant fails to reach inner areas.
Innovation Solution
The use of an additively manufactured core structure with a coarser microstructure and larger pores allows for rapid transport of molten silicon, facilitating complete infiltration of larger CMC structures by increasing permeability and ensuring uniform densification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional infiltration methods are used on thick preforms, then infiltration pathways close prematurely, but complete infiltration of larger structures cannot be achieved
Solution Approach 1:
The preform is segmented into two distinct regions with different microstructures: a first region with coarser particles and larger pores for rapid infiltrant transport, and a second region with finer particles for high-quality composite formation. This segmentation allows the infiltration process to proceed effectively through thick preforms by dividing the infiltration pathway into functional zones.
Solution Approach 2:
Different regions of the preform are given different local qualities in terms of particle size and pore structure. The first region (coarser) is optimized for infiltrant transport, while the second region (finer) is optimized for final composite quality. This local differentiation resolves the contradiction between achieving complete infiltration through thick sections and maintaining high composite quality.
2Reliability
If infiltration time is extended to reach inner areas of larger structures, then complete infiltration may be achieved, but production efficiency decreases
Solution Approach 1:
The preform is segmented into two distinct regions with different microstructures: a first region with coarser particles and larger pores for rapid infiltrant transport, and a second region with finer particles for high-quality composite formation. This segmentation allows the infiltration process to proceed effectively through thick preforms by dividing the infiltration pathway into functional zones.
Solution Approach 2:
The particle size parameter is changed between regions: larger particles in the first region create larger pores that increase permeability and accelerate infiltrant transport, while smaller particles in the second region provide the desired final microstructure. This parameter change enables rapid infiltration through thick preforms without sacrificing composite quality.
3Ease of manufacture
If uniform particle size is used throughout the preform, then manufacturing simplicity is maintained, but infiltration pathways close prematurely in thick sections
Solution Approach 1:
Different regions of the preform are given different local qualities in terms of particle size and pore structure. The first region (coarser) is optimized for infiltrant transport, while the second region (finer) is optimized for final composite quality. This local differentiation resolves the contradiction between achieving complete infiltration through thick sections and maintaining high composite quality.
Solution Approach 2:
The preform utilizes controlled porosity through different particle size distributions. The first region with coarser particles and larger pores maintains open infiltration pathways for efficient infiltrant transport, while the second region with finer particles provides the desired final microstructure. This porous structure design enables complete infiltration of thick preforms.
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 enables efficient infiltration of larger CMC structures in a shorter time, resulting in fully dense and high-quality components with complex geometries, suitable for high-temperature applications.
Implementation Method 1
densifying the composite panel through infiltration, wherein the infiltration comprises transport of an infiltrant through the core structure and into the composite face sheet
Implementation Method 2
rapid transport of molten silicon, facilitating complete infiltration of larger CMC structures
Data Source
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AI summary
A method of manufacturing a composite panel is provided. The method includes applying a composite face sheet to a first side of a core structure, the core structure comprising a plurality of first ceramic particles each having a first particle size that is within a first particle size range and the composite face sheet comprising a plurality of second ceramic particles each having a second particle size that is within a second particle size range, wherein the second particle size range is smaller than the first particle size range and densifying the composite panel through infiltration, wherein the infiltration comprises transport of an infiltrant through the core structure and into the composite face sheet.