Hollow Structures in Ceramic Matrix Composites
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Solution Overview
Problem
Conventional methods for creating cooling passages in ceramic matrix composites, such as using fugitive quartz rods or laser drilling, are limited to linear designs and often result in incomplete removal or brittleness issues, restricting the complexity and effectiveness of cooling systems in gas turbine components.
Innovation Solution
A method involving digital light processing (DLP) is used to form cores and cooling passages within ceramic matrix composites, allowing for non-linear geometries and the strategic placement of hollow structures, using materials like Si, SiO, and SiO2 with organic binders, and subsequent densification to create flexible and efficient cooling channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods (fugitive quartz rods or laser drilling) are used to create cooling passages, then the manufacturing process is simple, but the passages are limited to linear designs and suffer from incomplete removal or brittleness issues
Solution Approach 1:
The patent changes the material parameter from traditional fugitive materials (quartz rods) to a photosensitive resin composition that can be cured by light. This parameter change enables the formation of complex non-linear passages while maintaining ease of manufacture through photo-curing processes.
Solution Approach 2:
The patent replaces mechanical drilling or rod insertion methods with a photochemical curing process. The photosensitive resin is cured in-place using light exposure, eliminating the need for mechanical removal processes and enabling complex geometries without brittleness or incomplete removal issues.
2Reliability
If complex internal cooling passages are created to improve cooling efficiency, then thermal stress resistance improves, but the device complexity increases
Solution Approach 1:
The patent uses a photosensitive resin composition with specific properties (viscosity range, photo-curing characteristics) that allows complex geometries to be formed easily. The resin can be deposited and cured layer-by-layer or in-place, transforming complex passage structures from difficult-to-manufacture features into straightforward photochemical processes.
Solution Approach 2:
The patent performs preliminary action by forming the complex passage geometry within the resin matrix before final curing and integration into the ceramic matrix composite. The passages are pre-formed with exact complex geometries, eliminating the need for post-processing or complex assembly steps.
3Adaptability or versatility
If photosensitive resin composition is used to form cores and passages, then non-linear geometries are enabled, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces complex mechanical machining or molding processes with a photochemical curing process. The photosensitive resin can be deposited using simple methods and then cured in-place using light exposure, transforming a potentially complex manufacturing process into a straightforward photo-curing operation that enables non-linear geometries.
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 enables the formation of complex, non-linear cooling passages that enhance thermal stress resistance and cooling efficiency in gas turbine components, overcoming the limitations of traditional methods by allowing for more flexible design and complete removal of fugitive materials.
Implementation Method 1
a) at least partially covering a core having an organic binder and at least a silicon component with a reinforcing fiber material
Data Source
AI summary
The present disclosure relates to a method of fabricating a ceramic composite components. The method may include providing at least a first layer of reinforcing fiber material which may be a pre-impregnated fiber. An additively manufactured component may be provided on or near the first layer. A second layer of reinforcing fiber, which may be a pre-impregnated fiber may be formed on top the additively manufactured component. A precursor is densified to consolidates at least the first and second layer into a densified composite, wherein the additively manufactured material defines at least one cooling passage in the densified composite component.