In-Plane Slurry Infiltration for Thick Fibrous Composite Preforms
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Solution Overview
Problem
Infiltrating ceramic slurry into fibrous preforms used for aerospace brake stacks and heat sinks is challenging due to limited porosity, making it difficult for slurry particles to penetrate the preform layers in the axial direction.
Innovation Solution
A slurry infiltration system with a reservoir configured to orient the fibrous preform such that the in-plane direction is either vertical or perpendicular to the vertical direction, allowing the slurry to flow and infiltrate in the in-plane direction, facilitated by a cavity design that spaces the internal surface from the preform's outer diameter, enabling greater volume and particle size infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If infiltration is performed in the axial direction through the thickness of the preform, then the slurry particles must penetrate multiple layers, but the limited porosity makes penetration difficult and infiltration efficiency low
Solution Approach 1:
The patent changes the infiltration direction from the axial direction (through thickness) to the in-plane direction (radial direction). This dimensional change allows slurry to infiltrate through the larger porosity areas between fiber layers rather than against the compacted fiber structure, dramatically improving infiltration efficiency and reducing process difficulty
Solution Approach 2:
The patent uses a composite preform structure with specific fiber architecture that creates preferential infiltration paths in the in-plane direction. The composite structure combines high-strength fibers with controlled porosity distribution, enabling selective infiltration through the designed pore network while maintaining mechanical integrity
2Ease of manufacture
If the preform is infiltrated in the axial direction, then the process is difficult due to limited porosity, but changing to in-plane infiltration requires reconfiguring the entire infiltration system
Solution Approach 1:
The infiltration system is reconfigured to enable in-plane infiltration by orienting the preform such that the in-plane direction aligns with the gravity-driven slurry flow direction. This requires designing the mold cavity and slurry delivery system to accommodate horizontal or radial infiltration rather than vertical through-thickness infiltration
Solution Approach 2:
The system uses gravity-driven slurry flow (hydraulic principle) to infiltrate the preform in the in-plane direction. The slurry reservoir and delivery mechanism are positioned to allow slurry to flow radially or horizontally through the preform pores without requiring complex pressurization systems
3Reliability
If infiltration is performed in the axial direction, then outer surface sealing may occur before inner volume densification, but in-plane infiltration requires larger cavity spacing
Solution Approach 1:
By changing infiltration from axial to in-plane direction, the slurry penetrates through the larger inter-layer porosity paths, achieving more uniform densification throughout the preform volume. This prevents surface sealing issues because the infiltration paths are longer and more distributed throughout the material structure
Solution Approach 2:
The cavity design provides localized spacing between the slurry reservoir wall and the preform outer surface, creating optimal infiltration conditions at the infiltration front while maintaining compact overall system volume. The spacing is sufficient to allow slurry penetration but minimizes unnecessary cavity volume
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 allows for more efficient infiltration of larger particles and thicker preforms, reducing densification time and the risk of outer surface sealing before inner volume densification, thereby improving the manufacturing process for composite components like brake disks.
Implementation Method 1
Infiltrating the fibrous preform through a thickness of the fibrous preforms (i.e., in the axial direction) tends to be difficult, as the porosity or open area within the preform is limited, thereby making it difficult for the slurry particles to penetrate the layers of the fibrous preform
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
A system for infiltrating a fibrous preform in the in-plane direction and forming composite components are provided. A system for infiltrating a fibrous preform may include a slurry reservoir (202) defining a cavity (206) configured to receive a fibrous preform (130). The cavity may be configured such that an internal surface of the slurry reservoir is spaced apart from an outer diameter of the fibrous preform. A slurry inlet (208) may be formed in the slurry reservoir. The slurry inlet and the cavity may be configured such that a slurry (204) input into the cavity infiltrates the fibrous preform in an in-plane direction.