Perforation Tool for Fiber Preform Infiltration
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Solution Overview
Problem
The manufacturing of ceramic matrix composite (CMC) components, particularly SiC/SiC CMCs, faces challenges in infiltrating chemical reactants due to narrow pores in fiber preforms, which can be damaged during manipulation, necessitating additional tooling and methods to correct pore shape and facilitate infiltration.
Innovation Solution
A tool system comprising a first tool component, a second tool component, and a plunger assembly is used to perforate fiber preforms, with the plunger assembly translating a piercing element through the preform to form perforations, reducing damage and allowing for improved reactant infiltration during the chemical vapor infiltration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chemical vapor infiltration is used to manufacture CMC components, then matrix deposition is enabled, but narrow pores in fiber preforms prevent effective reactant infiltration
Solution Approach 1:
The patent applies preliminary action by creating perforations in the fiber preform before the chemical vapor infiltration process. These pre-formed holes provide direct pathways for reactant vapor to reach the fiber bundle interior, ensuring effective infiltration before the matrix deposition begins. This preliminary structural modification enables the subsequent matrix formation process to proceed efficiently.
2Ease of manufacture
If tooling is used to manipulate tows and correct pore shape, then infiltration is facilitated, but tows of the preform are damaged
Solution Approach 1:
The patent utilizes the inherent porous structure of the fiber preform by creating controlled perforations that maintain the overall integrity of the tow structure. The perforations are formed through the porous material without requiring manipulation or correction of the tow configuration, thereby avoiding damage while still enabling effective reactant infiltration through the created pathways.
3Manufacturing precision
If perforations are created in fiber preform, then reactant infiltration is improved, but risk of bulges increases
Solution Approach 1:
The patent applies local quality by creating perforations with specific dimensional characteristics (diameter, depth, spacing) that are optimized for reactant infiltration while minimizing their impact on overall preform stability. The perforations are designed with controlled local properties that allow uniform reactant distribution without causing excessive bulging or dimensional changes in the preform structure.
Data Source
AI summary
A tool and method for forming a perforation through a fiber preform includes a first and second tool components. Coaxial holes of the first and second tool components receive a plunger assembly that is translatable along the coaxial holes to perforate the fiber preform. Opposing surfaces of the first and second tool components circumscribe respective holes and contact the fiber preform during the perforation process.