Rare Earth Phosphate CMC Fibers for High-Temperature Oxidation
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Solution Overview
Problem
Ceramic matrix composite materials degrade when exposed to temperatures above 1200°C in oxidizing environments, such as those found in gas turbine engines, due to passive and active oxidation.
Innovation Solution
Incorporating rare earth phosphate ceramic fibers into the reinforcing fiber structure and optionally the ceramic matrix, which are manufactured using a sol-gel process, and infiltrating woven fibers with a ceramic matrix precursor slurry, followed by thermal treatment to form a stable composite material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional CMC materials are used to achieve lightweight and creep resistance at high temperatures, then mechanical performance is improved, but oxidation resistance deteriorates above 1200°C
Solution Approach 1:
The patent applies composite materials by combining rare earth phosphate fibers with conventional ceramic matrix materials. The rare earth phosphate fibers (containing elements like La, Ce, Pr, Nd, Sm, Eu, Gd, Dy, Er, Tm, Yb, Lu) are embedded in the ceramic matrix to create a composite structure that provides both the mechanical strength/creep resistance of conventional CMCs and the oxidation resistance of rare earth phosphates at temperatures above 1200°C
Solution Approach 2:
The patent changes the chemical composition parameters of the fiber reinforcement by introducing rare earth phosphate compounds. This parameter change transforms the material properties to achieve simultaneous high-temperature mechanical strength and oxidation resistance, resolving the contradiction between conventional CMC performance and oxidation stability
2Temperature
If CMC materials are exposed to oxidizing environments above 1200°C to meet high-temperature application requirements, then operational capability is improved, but material degradation accelerates
Solution Approach 1:
The patent converts the harmful oxidation effect into a beneficial protective mechanism. The rare earth phosphate fibers, when exposed to oxidizing environments above 1200°C, form protective oxide layers on their surface that prevent further oxidation of the underlying ceramic matrix, thus converting the potentially harmful oxidation into a protective barrier
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 resulting ceramic matrix composite material effectively resists oxidation and degradation at high temperatures, making it suitable for use in high-temperature industrial applications like gas turbine engine components.
Implementation Method 1
rare earth phosphate ceramic fibers, which are manufactured using a sol-gel process
Implementation Method 2
The sol-gel process involves the hydrolysis of metal alkoxides or salts
Implementation Method 3
infiltrating woven fibers with a ceramic matrix precursor slurry, followed by thermal treatment to form a stable composite material
Data Source
AI summary
Disclosed is a ceramic matrix composite (CMC) material including rare earth phosphate ceramic fibers embedded in a ceramic matrix, wherein the ceramic matrix also optionally includes a rare earth phosphate material. Methods for manufacturing the CMC material and gas turbine engine components formed of the CMC material are also disclosed.