Manifold Matrix Distribution for Ceramic Composites

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Solution Overview

Problem

Processing thick and complex ceramic matrix composite laminates for gas turbines is challenging due to porosity and silicon-rich zones, leading to crack propagation and premature interlaminar failures, especially in thick sections where matrix infiltration is incomplete and thermal inertia causes uneven solidification.

Innovation Solution

A ceramic matrix composite article and fabrication process utilizing a manifold with matrix distribution channels connected to a delivery interface, ensuring uniform matrix material distribution and infiltration, reducing porosity and free silicon, and providing interlaminar flexibility through a contoured manifold design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If melt infiltration is used to process thick and complex ceramic matrix composite laminates, then the laminates can be manufactured with ceramic matrix composite materials, but porosity and silicon-rich zones form leading to crack propagation and premature interlaminar failures

Engineering Contradiction:

Improvemanufacturability of thick and complex laminatesVSAvoidresistance to crack propagation and interlaminar failures

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention segments the matrix material delivery system into multiple distribution channels within the manifold, allowing controlled infiltration of matrix material into different regions of the thick laminate. This segmentation enables complete infiltration throughout the thickness while preventing porosity and silicon-rich zone formation that would otherwise occur with conventional single-point infiltration methods

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention implements local quality by providing matrix material through distributed channels at different locations and rates according to the specific infiltration needs of each region. The manifold channels are configured to deliver matrix material locally to where it is needed in thick sections, ensuring uniform infiltration and preventing the formation of defective regions while maintaining manufacturing feasibility

Inventive Principle:

Principle #3Local quality

2Productivity

If conventional melt infiltration is used for thick sections, then manufacturing can proceed, but matrix material fails to fill effectively resulting in micro-porosity in the matrix

Engineering Contradiction:

Improvemanufacturing throughputVSAvoidinfiltration completeness and porosity control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention transitions from conventional single-point or surface infiltration to a three-dimensional network of distribution channels embedded within the manifold. This dimensional expansion allows matrix material to reach all regions of thick laminates simultaneously through multiple pathways, achieving complete infiltration and eliminating micro-porosity while maintaining manufacturing efficiency

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Shape

If thick sections are processed with conventional methods, then the component geometry can be achieved, but thermal inertia creates time-varying solidification fronts with undesirable free silicon zones

Engineering Contradiction:

Improvecomplex geometry capabilityVSAvoiduniformity of solidification and phase distribution

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The invention applies preliminary action by pre-positioning the manifold with its distribution channels within the laminate structure before matrix infiltration. This allows controlled delivery of matrix material to compensate for thermal inertia effects during solidification, ensuring uniform composition and preventing the formation of undesirable free silicon zones in the final solidified structure

Inventive Principle:

Principle #10Preliminary action

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

The solution improves matrix infiltration, reduces porosity and premature failures, enabling ceramic matrix composites to operate at higher temperatures with increased efficiency and performance, and enhances interlaminar flexibility in thick sections.

Implementation Method 1

The manifold includes one or more matrix distribution channels operably connected to a delivery interface, the delivery interface configured for providing matrix material to one or more of the ceramic matrix composite plies

Methodology Applied

Scientific EffectFluid flow through channels:

Data Source

PatentUS9926791B2Ceramic matrix composite article and process of fabricating a ceramic matrix composite article

Publication Date: 2018.03.27 GE INFRASTRUCTURE TECH LLC

AI summary

A ceramic matrix composite article and a process of fabricating a ceramic matrix composite are disclosed. The ceramic matrix composite article includes a matrix distribution pattern formed by a manifold and ceramic matrix composite plies laid up on the matrix distribution pattern, includes the manifold, or a combination thereof. The manifold includes one or more matrix distribution channels operably connected to a delivery interface, the delivery interface configured for providing matrix material to one or more of the ceramic matrix composite plies. The process includes providing the manifold, forming the matrix distribution pattern by transporting the matrix material through the manifold, and contacting the ceramic matrix composite plies with the matrix material.