Dual-Walled CMC Component With Integral Cooling
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Solution Overview
Problem
Existing ceramic matrix composites (CMCs) for high-temperature applications, such as gas turbine engine components, face challenges in maintaining uniform operating temperatures and structural stability due to lack of effective cooling techniques, especially for complex geometric parts.
Innovation Solution
A dual-walled CMC component with a hollow core and outer layer separated by a ceramic slurry-cast architecture, featuring through-thickness cooling holes that create an integral cooling pathway, allowing for efficient heat dissipation and enhanced mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If continuous tubes are placed into the fibrous preform during fabrication, then cooling capability is provided, but structural stability and manufacturing complexity are compromised
Solution Approach 1:
The patent utilizes the inherent porosity of the fibrous preform structure to accommodate cooling channels. The void spaces between ceramic fibers are used to form the cooling pathway, eliminating the need for separate continuous tubes while maintaining structural integrity. This approach transforms the preform's natural porous architecture into a functional cooling system.
Solution Approach 2:
The invention merges the structural framework and cooling system into a single integrated component. The cooling channels are formed directly within the preform structure itself, combining what were previously separate elements (structural preform and cooling tubes) into one unified architecture, thereby eliminating manufacturing complexity associated with assembling multiple components.
2Temperature
If continuous tubes are placed into the fibrous preform during fabrication, then cooling capability is provided, but device complexity increases
Solution Approach 1:
The patent utilizes the inherent porosity of the fibrous preform structure to accommodate cooling channels. The void spaces between ceramic fibers are used to form the cooling pathway, eliminating the need for separate continuous tubes while maintaining structural integrity. This approach transforms the preform's natural porous architecture into a functional cooling system.
Solution Approach 2:
The invention merges the structural framework and cooling system into a single integrated component. The cooling channels are formed directly within the preform structure itself, combining what were previously separate elements (structural preform and cooling tubes) into one unified architecture, thereby eliminating manufacturing complexity associated with assembling multiple components.
3Weight of moving object
If CMC parts are used to replace metallic flowpath components, then weight is reduced, but cooling capability must be developed to maintain temperature uniformity
Solution Approach 1:
The patent utilizes the inherent porosity of the fibrous preform structure to accommodate cooling channels. The void spaces between ceramic fibers are used to form the cooling pathway, eliminating the need for separate continuous tubes while maintaining structural integrity. This approach transforms the preform's natural porous architecture into a functional cooling system.
Solution Approach 2:
The invention creates a three-dimensional cooling network within the CMC structure by forming channels that extend through the thickness and along the length of the component. This multi-dimensional cooling approach efficiently distributes coolant throughout the part, maintaining temperature uniformity across complex geometries while preserving the weight advantages of CMC materials.
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
The dual-walled CMC component maintains uniform temperature, reduces thermal gradients, and provides improved out-of-plane strength and stiffness, making it suitable for high-temperature applications like gas turbine engine components.
Implementation Method 1
The ceramic slurry-cast architecture defines a cooling fluid path over an outer surface of the CMC core that connects the interior channel(s) to an external environment of the dual-walled CMC component
Implementation Method 2
The CMC core further includes a plurality of through-thickness inner cooling holes in fluid communication with the at least one interior channel
Data Source
AI summary
A dual-walled ceramic matrix composite (CMC) component comprises: a CMC core having a hollow shape enclosing at least one interior channel; and a CMC outer layer overlying and spaced apart from the CMC core by a ceramic slurry-cast architecture positioned therebetween. Each of the CMC core and the CMC outer layer comprises ceramic fibers in a ceramic matrix. The CMC core further includes a plurality of through-thickness inner cooling holes in fluid communication with the at least one interior channel. The ceramic slurry-cast architecture defines a cooling fluid path over an outer surface of the CMC core that connects the interior channel(s) to an external environment of the dual-walled CMC component. The CMC outer layer may also include a plurality of through-thickness outer cooling holes in fluid communication with the cooling fluid path, thereby extending the cooling fluid path through the CMC outer layer.