Floating Tooling Assembly for Uniform CVI Preform Infiltration

Solution Overview

Problem

Existing tooling for chemical vapor infiltration (CVI) struggles to uniformly infiltrate vaporous precursors into complex-shaped fibrous preforms, such as turbine airfoils, due to holes being too long, leading to insufficient precursor infiltration at certain locations.

Innovation Solution

A multipiece tooling assembly comprising an outer tooling fixture with large windows and an inner tooling fixture with uniformly sized holes conformal to the preform geometry, allowing for minimal obstruction and uniform precursor flow, supported by a floating attachment mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If uniform hole lengths are used in tooling for simple preform shapes, then the tooling structure is simple, but the precursor infiltration is insufficient at certain locations when used with complexly-shaped preforms

Engineering Contradiction:

Improvetooling structure simplicityVSAvoidprecursor infiltration uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The tooling is divided into multiple segments (first portion and second portion) that can be removably attached together. Each portion can have holes of different lengths optimized for specific regions of the preform, allowing the tooling to accommodate complex geometries while maintaining manufacturing feasibility through modular construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the tooling are designed with locally optimized hole characteristics (different lengths, patterns, or configurations) to match the specific geometric requirements of different regions of the complex preform, ensuring uniform precursor infiltration across all areas regardless of preform shape complexity

Inventive Principle:

Principle #3Local quality

2Length of moving object

If holes are made longer to reach complex preform geometries, then the precursor can reach deeper areas, but the hole length becomes excessive leading to insufficient infiltration at certain locations

Engineering Contradiction:

Improvehole lengthVSAvoidprecursor infiltration uniformity

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The tooling is divided into multiple segments (first portion and second portion) that can be removably attached together. Each portion can have holes of different lengths optimized for specific regions of the preform, allowing the tooling to accommodate complex geometries while maintaining manufacturing feasibility through modular construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the tooling are designed with locally optimized hole characteristics (different lengths, patterns, or configurations) to match the specific geometric requirements of different regions of the complex preform, ensuring uniform precursor infiltration across all areas regardless of preform shape complexity

Inventive Principle:

Principle #3Local quality

3Device complexity

If tooling with uniform hole lengths is used for complex preforms, then the tooling design is straightforward, but the precursor flow is obstructed at certain locations

Engineering Contradiction:

Improvetooling design complexityVSAvoidprecursor infiltration efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The tooling is divided into multiple segments (first portion and second portion) that can be removably attached together. Each portion can have holes of different lengths optimized for specific regions of the preform, allowing the tooling to accommodate complex geometries while maintaining manufacturing feasibility through modular construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the tooling are designed with locally optimized hole characteristics (different lengths, patterns, or configurations) to match the specific geometric requirements of different regions of the complex preform, ensuring uniform precursor infiltration across all areas regardless of preform shape complexity

Inventive Principle:

Principle #3Local quality

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

Ensures uniform infiltration of vaporous precursors throughout complex-shaped preforms, maintaining preform shape and facilitating the deposition of ceramic matrix composites with improved uniformity and efficiency.

Implementation Method 1

CVI is a commonly used densification technique practiced in industry. Holes in the tooling allow vaporous precursors to infiltrate into the preform for the deposition of a ceramic matrix.

Methodology Applied

Scientific EffectChemical vapor infiltration:

Implementation Method 2

Holes in the tooling allow vaporous precursors to infiltrate into the preform for the deposition of a ceramic matrix.

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS12392037B2Floating tooling assembly for chemical vapor infiltration

Publication Date: 2025.08.19 RTX CORP

AI summary

A tooling assembly suitable for use in infiltrating a fibrous preform comprises an outer tooling fixture and an inner tooling fixture. The outer tooling fixture comprises a first portion removably attached to a second portion, and a first pair of oppositely disposed windows defined by the first portion and the second portion. Each of the first portion and the second portion comprise a base with a recess. The inner tooling fixture comprises a body defined by at least one portion, the body configured to at least partially surround the fibrous preform, a plurality of holes extending through a thickness of the at least one portion, each hole of the plurality of holes having a length (L) and a diameter (D), and a first neck region engageable with a recess of the first portion or the second portion.