Composite Void Repair Using Through-Thickness Filler Flow Paths
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Solution Overview
Problem
Repairing voids in composite components, such as ceramic matrix composite (CMC) materials used in gas turbine engines, is challenging due to the difficulty in filling voids formed during processing or damage, as conventional methods like re-processing or machining can degrade material properties.
Innovation Solution
A method involving creating a flow path through the void in the composite component, applying a filler material, and processing it with melt infiltration to fill and repair the void, ensuring the flow path extends completely through the component to retain the filler material during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional re-processing methods are used to fill voids, then the void filling process is simple, but the filler material cannot fully fill the void and material properties are degraded
Solution Approach 1:
The method creates flow paths through the void before applying filler material, preparing the structure in advance to enable complete filler infiltration. This preliminary action of creating access channels allows the filler to reach and completely fill the void space without compromising the surrounding matrix material.
Solution Approach 2:
The flow path acts as an intermediary structure that facilitates the delivery of filler material to the void. By introducing this intermediate feature, the method enables controlled material transport through the component thickness, ensuring complete void filling while maintaining the integrity of the original matrix.
2Manufacturing precision
If machining out the void is performed to remove damaged material, then the void is completely removed, but the material properties of the composite component are acceptably degraded
Solution Approach 1:
Instead of extracting or removing the void through machining, the method extracts the problem by creating flow paths that allow filler material to occupy and eliminate the void space. This approach removes the defect without requiring material extraction that would degrade the composite structure.
Solution Approach 2:
The method changes the physical state and distribution of filler material by introducing flow paths, allowing the material to infiltrate and fill the void space. This parameter change in material delivery enables complete void elimination while preserving the surrounding composite material properties.
3Manufacturing precision
If a flow path is created through the void, then the filler material can be applied effectively, but additional processing steps are required
Solution Approach 1:
The flow path creation is performed as a preliminary action before filler material application, establishing the necessary infrastructure for effective material delivery. This sequential approach, while adding a step, ensures subsequent filler application is highly effective and complete.
Solution Approach 2:
The flow path serves as an intermediary structure that simplifies the overall repair process by providing a controlled delivery mechanism for filler material. Although it adds a structural element, it streamlines the filler application process and ensures complete void filling.
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 method effectively fills and repairs voids in composite components, maintaining material integrity and properties, thereby enhancing the structural soundness of components like turbine blades and nozzles in gas turbine engines.
Implementation Method 1
processing the composite component having the filler material within the flow path to densify the filler material and the composite component
Implementation Method 2
processing the composite component having the filler material within the flow path to densify the filler material and the composite component
Data Source
AI summary
Methods for repairing composite component voids are provided. For example, one method comprises locating a void in a composite component and subjecting the composite component to a process for repair. The process for repair includes creating a flow path through the void, applying a filler material to the composite component at the flow path, and processing the composite component having the filler material. In some embodiments, the flow path has a first opening on a first side of the composite component and a second opening on a second, opposite side of the composite component. In other embodiments, at least one portion of the flow path extends at a first angle with respect to a lateral direction defined by the CMC component, and at least another portion extends at a second angle with respect to the lateral direction.