Pyrolyzed Preform Mechanical Treatment for Ceramic Matrix Composites
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Solution Overview
Problem
Ceramic matrix composites used in harsh environments such as gas turbines face mechanical and thermal stresses that shorten their service life due to inadequate matrix infiltration and durability.
Innovation Solution
A method involving the formation of a preform by layering fibers with resins, applying heat or electromagnetic radiation for curing, pyrolyzing the resin to create a porous matrix, and applying mechanical stimuli like vibrations or ultrasonic energy to enhance infiltration of a densification material, resulting in improved matrix infiltration and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods are used, then production process is simple, but matrix infiltration is inadequate leading to poor durability
Solution Approach 1:
The preform is mechanically treated (vibration, ultrasonic energy, or local explosions) before the infiltration step to create a porous structure. This preliminary action prepares the preform to better receive and absorb the infiltration material, improving matrix infiltration and durability without complicating the overall process flow
Solution Approach 2:
The invention creates a porous structure in the preform through mechanical treatment methods (vibration, ultrasonic energy, or local explosions) applied before infiltration. This porous structure increases the surface area and pathways for infiltration material to penetrate into the preform, achieving better matrix infiltration and improved durability
2Manufacturing precision
If infiltration material is applied without mechanical treatment, then process is straightforward, but density and uniformity are insufficient
Solution Approach 1:
The preform is subjected to mechanical vibration or ultrasonic energy treatment before infiltration. This mechanical treatment creates a porous structure that facilitates uniform penetration of the infiltration material throughout the preform, improving density and uniformity while maintaining operational simplicity
Solution Approach 2:
Local explosions (pneumatic impact) are applied to the preform before infiltration to create a porous structure. This pneumatic treatment opens up pathways within the preform, enabling more uniform and complete infiltration material penetration without complicating the process
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 enhances the mechanical, thermal, and optical properties of the ceramic matrix composite by achieving higher density and uniformity, thereby extending its service life in harsh conditions.
Implementation Method 1
applying heat or electromagnetic radiation to at least partially cure the first and second resins
Implementation Method 2
applying heat to pyrolyze at least a portion of the resin from the cured preform
Implementation Method 3
A mechanical stimulus including at least one of controlled drying, local explosions, shaking, vibration, or ultrasonic energy is applied to the pyrolyzed preform
Implementation Method 4
A mechanical stimulus including at least one of controlled drying, local explosions, shaking, vibration, or ultrasonic energy is applied to the pyrolyzed preform
Data Source
AI summary
A method of making a preform and preform formed by the method. The method includes providing a first pre-preg ply including at least a first fiber and a first resin. The method also includes providing a second pre-preg ply including at least a second fiber and a second resin over at least a portion of the first pre-preg ply. Heat or electromagnetic radiation is used to at least partially cure the first and second resins to form a cured preform. Heat is applied to pyrolyze at least a portion of the resin of the cured preform to form a pyrolyzed preform. A mechanical stimulus including at least one of controlled drying, local explosions, or ultrasonic energy is applied to the pyrolyzed preform. The mechanically treated pyrolyzed preform is subsequently densified by melt infiltration to form a densified preform.