Method and ceramic component
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Solution Overview
Problem
Existing methods for forming ceramic matrix composites often limit the control over microstructure and thermal conductivity, making it difficult to achieve enhanced densification and thermal conductivity in components like turbine engine parts.
Innovation Solution
A method involving vapor infiltration to deposit a ceramic coating with high thermal conductivity within a porous fibrous structure, followed by transfer molding with heated liquid glass or glass/ceramic material to create a composite with tailored properties, including residual porosity control and selective crystallization for enhanced thermal resistance and dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vapor infiltration is used to deposit ceramic coating within porous fibrous structure, then thermal conductivity is improved, but residual porosity remains which limits densification
Solution Approach 1:
The patent creates a composite structure combining ceramic coating (for thermal conductivity) with glass/ceramic matrix (for densification). The vapor infiltration deposits ceramic coating on fibers, then liquid glass or glass/ceramic is infiltrated into residual porosity, forming a composite that achieves both high thermal conductivity and complete densification.
Solution Approach 2:
The method utilizes the porous fibrous structure as a scaffold that allows controlled infiltration. The residual interconnected porosity after vapor infiltration is deliberately used to receive the liquid glass or glass/ceramic material, transforming the porous structure into a dense composite.
2Manufacturing precision
If liquid glass or glass/ceramic material is deposited using transfer molding, then densification is enhanced, but thermal conductivity may be reduced due to lower thermal conductivity of glass material
Solution Approach 1:
The patent applies different materials to different regions: ceramic coating with high thermal conductivity is deposited on fibers through vapor infiltration, while liquid glass or glass/ceramic is infiltrated into the interstitial porosity. This spatial differentiation ensures that thermal conductivity is maintained through the ceramic network while densification is achieved through glass infiltration.
Solution Approach 2:
The final composite combines ceramic phases (for thermal conductivity) with glass/ceramic matrix (for densification and mechanical properties). The synergistic combination allows the material to achieve both complete densification and high thermal conductivity.
3Reliability
If ceramic coating is deposited to form thermal transfer network, then thermal conductivity is improved, but microstructure control is limited by processing technique
Solution Approach 1:
The fabrication process is segmented into distinct stages: vapor infiltration for ceramic coating deposition, followed by liquid glass or glass/ceramic infiltration. Each stage independently controls specific microstructural features, allowing precise tailoring of the final composite microstructure for optimized thermal conductivity and mechanical properties.
Solution Approach 2:
The method enables control of microstructure through parameter adjustments in each infiltration stage. Vapor infiltration parameters (temperature, pressure, precursor flow) control ceramic coating morphology, while liquid infiltration parameters (viscosity, pressure, temperature) control matrix distribution, providing versatile microstructure control.
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 method enables the fabrication of ceramic components with improved thermal conductivity, densification, and other target properties, such as enhanced thermal resistance and corrosion resistance, by creating a composite structure with a ceramic coating acting as a thermal transfer network and glass/ceramic material providing additional benefits.
Implementation Method 1
The infiltration of the precursor(s) is driven by diffusion, an imposed external gas pressure, an imposed vacuum or a combination of these.
Implementation Method 2
a ceramic coating is deposited using vapor infiltration within pores of a porous structure
Implementation Method 3
The liquid glass or glass/ceramic material is then cooled to form a solid glass or glass/ceramic material
Data Source
Figure 1~2(C)
AI summary
A method of fabricating a ceramic component (40) includes using vapor infiltration to deposit a ceramic coating (48) within pores (46) of a porous structure (42) to form a preform body (50) with residual interconnected porosity (52). Transfer molding is then used to deposit a heated, liquid glass or glass/ceramic material (54) into the residual interconnected porosity (52). The liquid ceramic or ceramic/glass material (54) is then solidified to form a ceramic component (40).