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 composites used in gas turbine engines, is challenging due to difficulties in filling voids without degrading the material properties, as conventional methods like re-processing or machining can be ineffective and may lead to unacceptable material weakening.
Innovation Solution
A method involving the creation of a flow path through the void, extending completely through the component, to allow for the application and infiltration of a filler material, followed by processing, such as melt infiltration, to effectively fill and repair the void while minimizing impact on the component's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional re-processing methods are used to fill voids, then the void may be filled, but the material properties are degraded
Solution Approach 1:
The method creates a flow path through the void before applying the filler material. This preliminary action of establishing the flow path allows the filler material to be delivered directly to the void location, ensuring complete filling while minimizing the amount of material removal and reprocessing needed, thereby preserving material properties.
Solution Approach 2:
The flow path acts as an intermediary structure that facilitates the delivery of filler material to the void. By creating this intermediate flow path, the method enables precise material delivery without requiring extensive machining or reprocessing of the surrounding composite material, thus maintaining material integrity while achieving complete void filling.
2Manufacturing precision
If machining out the void is performed, then the void is removed, but the material properties are unacceptable degraded
Solution Approach 1:
Instead of machining out the void, the method extracts only the minimal necessary material to create a flow path, then fills the void with filler material. This selective extraction approach removes the void while preserving the surrounding composite material properties, avoiding the extensive material removal and degradation associated with conventional machining methods.
3Ease of manufacture
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 is created as a preliminary step before filler material application. This preliminary action simplifies the subsequent filler material application process by providing a direct delivery route to the void, making the overall manufacturing process easier despite the additional initial step.
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 allows for the successful filling and repair of voids in composite components, enhancing their structural integrity and maintaining material properties, thereby improving the reliability of gas turbine engine components.
Implementation Method 1
processing the composite component having the filler material within the flow path to a process that includes melt infiltration
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.