Liquid Infusion Molded Ceramic Matrix Composites
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Solution Overview
Problem
Current methods for manufacturing ceramic matrix composites (CMCs) face challenges in maintaining proper fiber spacing and continuity during near net shape manufacturing, leading to defective products due to material compression or movement in tooling, and inadequate fiber volume fraction control.
Innovation Solution
The method involves using a particulate material and fugitive binder to maintain fiber spacing and integrity during the liquid infusion process, allowing for near net shape manufacturing with improved fiber alignment and reduced subsequent processing needs, using techniques like vacuum infusion and resin transfer molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If near net shape matrix infusion methods (RTM) are used to reduce machining, then productivity is improved, but manufacturing precision deteriorates due to fiber bundling and defective products
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic fibers with a sizing agent before infusion. This sizing layer is applied in advance to prevent fiber bundling during the infusion process, ensuring proper fiber spacing is maintained from the outset rather than attempting to correct bundling issues after they occur.
Solution Approach 2:
The sizing agent acts as an intermediary substance between the ceramic fibers and the matrix material. This intermediary layer prevents direct adhesion between fibers that would cause bundling, while still allowing proper matrix infiltration, thus resolving the contradiction between productivity and manufacturing precision.
2Device complexity
If unidirectional plies are used in CMC laminates, then manufacturing complexity is reduced, but reliability deteriorates due to ply discontinuity and lack of cross-fiber support
Solution Approach 1:
The patent applies local quality by introducing cross-fiber elements at specific locations where unidirectional plies are laid in tooling. These localized cross-fiber regions provide support and maintain continuity without requiring the entire laminate structure to be complex woven or stitched constructions, thus balancing manufacturing simplicity with structural reliability.
3Manufacturing precision
If too much material is present in tooling, then manufacturing precision improves with complete fiber coverage, but reliability deteriorates due to compression and movement of material when tooling is closed
Solution Approach 1:
The patent applies preliminary action by pre-positioning spacers between ceramic fibers during fiber placement. These spacers are installed in advance to maintain proper spacing and prevent material compression when the tooling is closed, ensuring both complete coverage and structural stability during the infusion process.
4Reliability
If too less material is present in tooling, then reliability improves by avoiding compression, but manufacturing precision deteriorates resulting in defective products
Solution Approach 1:
The patent applies self-service by using a vacuum infusion process where the liquid matrix material is drawn into the tooling through vacuum pressure. This self-infusion mechanism ensures that the exact amount of material needed is automatically introduced without overfilling or underfilling, achieving both complete coverage and avoidance of compression without requiring precise manual material measurement.
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 production of CMCs with tighter tolerances and higher yields, reducing machining requirements and improving efficiency by maintaining desired fiber spacing and continuity, suitable for high-performance components like gas turbine engine parts.
Implementation Method 1
removing at least a portion of the binder prior to applying the matrix system to the ceramic composite and removing at least part of the binder, in some embodiments, comprises sublimation, evaporation, volatilization, or combinations thereof
Implementation Method 2
removing at least a portion of the binder prior to applying the matrix system to the ceramic composite and removing at least part of the binder, in some embodiments, comprises sublimation, evaporation, volatilization, or combinations thereof
Implementation Method 3
removing at least a portion of the binder prior to applying the matrix system to the ceramic composite and removing at least part of the binder, in some embodiments, comprises sublimation, evaporation, volatilization, or combinations thereof
Implementation Method 4
applying a matrix system to the ceramic composite; treating the matrix system to prepare a set ceramic composite
Implementation Method 5
Applying an infiltrant to the set ceramic matrix composite, and densifying the set ceramic matrix composite to form a densified ceramic matrix composite, in some embodiments, is performed using CVI, MI, PIP, or a combination thereof
Implementation Method 6
Applying an infiltrant to the set ceramic matrix composite, and densifying the set ceramic matrix composite to form a densified ceramic matrix composite, in some embodiments, is performed using CVI, MI, PIP, or a combination thereof
Implementation Method 7
Applying an infiltrant to the set ceramic matrix composite, and densifying the set ceramic matrix composite to form a densified ceramic matrix composite, in some embodiments, is performed using CVI, MI, PIP, or a combination thereof
Data Source
AI summary
Methods for preparing ceramic products using liquid infusion technology and products formed from the same are provided. The methods and products include the incorporation of a particulate material and binder between ceramic fibers such that the fibers may be properly spaced during formation of the ceramic product. Ceramic matrix composite products can thereby be provided using near net shaping methods.