Filament Winding Apparatus for Ceramic Matrix Composites
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Solution Overview
Problem
The high production cost and lengthy processing cycles of current Ceramic Matrix Composites (CMCs), particularly dual-fiber CMCs, limit their adoption in temperature-resistant applications like gas turbines and hypersonic engines due to methods like CVI and PIP requiring 20 days or more for consolidation.
Innovation Solution
A filament winding apparatus and method using a monofilament feed track, fiber yarn feed track, and heater assembly to wind ceramic monofilament strands and glass-impregnated fiber yarns onto a mandrel, where the heater softens glass particulates under pressure from tensioned monofilaments to consolidate them into a dual-fiber ceramic matrix composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical vapor infiltration (CVI) or polymer infiltration and pyrolysis (PIP) is used to process dual-fiber CMC components, then consolidation is achieved, but the processing cycle takes 20 days or longer
Solution Approach 1:
The invention changes the physical-chemical parameters of the glass particulates by heating them to their softening point, transforming them from a rigid particulate state to a viscous molten state. This parameter change enables rapid consolidation without requiring the extended time periods of CVI or PIP processes, reducing processing time from 20+ days to a fraction of that time while achieving sufficient densification.
Solution Approach 2:
The invention utilizes the phase transition of glass particulates from solid to molten state through heating. By heating the glass particulates to their softening temperature, they transition to a viscous state that allows them to flow and consolidate around the fiber tows and monofilaments. This phase transition mechanism enables rapid consolidation compared to the gradual infiltration processes of CVI and PIP.
2Productivity
If glass transfer molding is used to process CMC components, then processing speed is faster than CVI and PIP, but the process becomes much more expensive and resource intensive
Solution Approach 1:
The invention segments the consolidation process into distinct functional zones: a heating zone that softens the glass particulates and a consolidation zone where tensioned monofilaments apply pressure. This segmentation allows the process to achieve rapid consolidation similar to glass transfer molding while using simpler, more cost-effective equipment and materials that do not require the extensive resource input of traditional glass transfer molding.
Solution Approach 2:
The invention uses tensioned ceramic monofilaments as an intermediary mechanism to apply consolidation pressure to the heated glass-impregnated fiber tows. These monofilaments serve as the pressure application medium, replacing the complex molding equipment required in glass transfer molding, thereby reducing device complexity and resource intensity while maintaining high processing speed.
3Manufacturing precision
If multiple long processing cycles are used to achieve sufficient densification of CMCs, then consolidation quality is improved, but production cost increases significantly
Solution Approach 1:
The invention implements continuous useful action by heating the glass particulates to their softening point and immediately applying consolidation pressure while the glass is in its viscous state. This continuous process eliminates the need for multiple separate processing cycles, achieving sufficient densification in a single continuous operation. The tensioned monofilaments maintain continuous pressure on the consolidating material, ensuring high densification quality while reducing production time and cost.
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 reduces production time and cost by efficiently consolidating dual-fiber CMCs, enabling their use in high-temperature components such as turbine engine parts and lightweight armor with improved mechanical properties.
Implementation Method 1
The heater assembly is disposed within or adjacent to the mandrel and is adapted to heat at least the glass particulates such that pressure from the wound array of glass monofilaments is sufficient to consolidate the glass particulates
Implementation Method 2
pressure from the wound array of glass monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite
Data Source
AI summary
An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).