Disposable Paper Pattern for CMC Preform Conformation
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Solution Overview
Problem
The existing methods for manufacturing ceramic matrix composite (CMC) parts using graphite conformation tooling are costly, fragile, have a limited lifetime, and require frequent replacement, due to high machining costs, fragility, and bulkiness, which limits their efficiency in producing parts for high-temperature applications like aerospace and industrial gas turbines.
Innovation Solution
A method involving shaping a fiber texture in a heated metal mold, pre-impregnating it with a transient material, cooling, and then heat-treating it to form a porous shell, which allows for consolidation by chemical vapor infiltration without the need for graphite tooling, reducing production costs and improving dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If graphite conformation tooling is used for consolidating fiber preforms, then the fiber texture can be properly conformed during interphase deposition, but the tooling becomes costly, fragile, and requires frequent replacement
Solution Approach 1:
The patent replaces expensive, fragile graphite tooling with a disposable paper pattern that is inexpensive to manufacture and replace. The paper pattern serves its conformation function during the consolidation process and is then discarded, eliminating the reliability issues associated with graphite tooling while maintaining manufacturing precision through the use of a flexible, conformable paper substrate
Solution Approach 2:
The patent substitutes the mechanical graphite tooling system with a chemical/thermal system where a paper pattern is impregnated with resin and cured in place. This replacement transforms the mechanical conformation approach into a chemical bonding approach, where the resin-cured paper pattern maintains fiber texture conformation without requiring the mechanical strength and durability of graphite tooling
2Manufacturing precision
If graphite conformation tooling is used, then the fiber preform can be consolidated, but the production cost increases significantly
Solution Approach 1:
The patent employs a paper pattern instead of expensive graphite tooling. The paper is inexpensive, readily available, and can be easily manufactured into the required shapes. Although disposable, its low cost per unit eliminates the need for costly graphite tooling while achieving the same preform consolidation quality
Solution Approach 2:
The patent changes the material parameter from graphite to paper-resin composite. This parameter change transforms the tooling from a expensive, durable material to an inexpensive, disposable material system, significantly reducing production costs while maintaining the ability to consolidate fiber preforms with proper conformation
3Shape
If graphite conformation tooling is used, then the fiber texture is maintained, but the tooling becomes bulky and requires frequent replacement of gripping members
Solution Approach 1:
The patent replaces complex graphite tooling with simple paper patterns that are discarded after use. This eliminates the need for bulky gripping members and complex assembly structures, as the paper pattern is simply placed within the fiber preform and cured in place, significantly reducing device complexity
Solution Approach 2:
The patent extracts the conformation function from the graphite tooling structure and transfers it to the paper pattern itself. By taking out the gripping and support functions from the tooling design, the patent simplifies the overall device structure, eliminating bulky components and complex assembly requirements
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 method significantly reduces production costs, enhances the mechanical strength and longevity of the tooling, and optimizes dimensional control, allowing for the production of CMC parts without the need for recurring replacement of graphite conformers, thereby improving the efficiency and reliability of the manufacturing process.
Implementation Method 1
shaping a fiber texture in a heated metal mold
Implementation Method 2
cooling the mold
Implementation Method 3
heat-treating the coated fiber preform so as to form a porous shell around the fiber preform by consolidation of the slurry and so as to remove the transient or fugitive material present in the fiber preform
Implementation Method 4
remove the transient or fugitive material present in the fiber preform
Implementation Method 5
consolidating the fiber preform by gas-phase chemical infiltration
Data Source
AI summary
A method for producing a consolidated fiber preform intended for the manufacture of a part made of composite material, includes shaping a fiber texture in a heated metal mold, the texture being pre-impregnated with a transient or fugitive material, or shaping a fiber texture in a metal mold and injecting a transient or fugitive material into the fiber texture held in shape in the metal mold, cooling the mold, removing the set fiber preform from the mold, coating the fiber preform with a slurry containing a powder of ceramic or carbon particles, heat-treating the coated fiber preform so as to form a porous shell around the fiber preform by consolidation of the slurry and so as to remove the transient or fugitive material present in the fiber preform, consolidating the fiber preform by gas-phase chemical infiltration.