Additive Slurry Deposition for CMC Geometries
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Solution Overview
Problem
Existing methods for manufacturing ceramic matrix composites (CMCs) face challenges in forming complex geometries and avoiding damage during machining, particularly when dealing with fiber bundles, which can weaken the components.
Innovation Solution
A method involving the formation of a stacked powder structure with alternating binder and powder layers, using a system that includes a dispenser for precise binder application and a roller for powder deposition, allowing for the creation of porous ceramic preforms that can be infiltrated with molten material to form densified CMC components with precise geometries and reduced fiber damage during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional machining methods are used on CMC components, then complex geometries can be achieved, but fiber bundle damage occurs which weakens the components
Solution Approach 1:
The patent applies preliminary action by forming the complex geometries directly during the additive manufacturing process rather than through subsequent machining. The slurry is deposited layer-by-layer to create precise geometric features before the component is fully cured, eliminating the need for post-manufacturing machining that would damage fiber bundles.
Solution Approach 2:
The patent replaces mechanical machining operations with an additive manufacturing process using slurry deposition. Instead of mechanically removing material through cutting or drilling (which damages fibers), the complex geometries are built up by depositing slurry that is then selectively removed or cured to form the desired shape.
2Manufacturing precision
If additive layer method is used to apply slurry-based features, then precise geometries and fiber protection are achieved, but manufacturing process complexity increases
Solution Approach 1:
The patent applies universality by using a single additive manufacturing system that performs multiple functions: depositing slurry, forming geometries, and protecting fiber bundles all in one process. The slurry deposition system serves as both the shaping mechanism and the fiber protection method, eliminating the need for separate machining operations.
Solution Approach 2:
The patent applies parameter changes by controlling the viscosity, composition, and deposition parameters of the slurry to achieve precise geometries. By adjusting slurry properties such as particle size distribution, binder content, and solvent composition, the process achieves high manufacturing precision while maintaining a unified manufacturing approach.
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 approach enables the production of CMC components with improved toughness and strength by avoiding fiber bundle damage and allowing for precise, complex geometries, enhancing their mechanical and thermal properties.
Implementation Method 1
depositing a binder to form a binder layer on a substrate or on the powder layer
Implementation Method 2
heating the stacked powder structure and pyrolyzing the binder
Implementation Method 3
the porous ceramic preform configured to be infiltrated by a molten material
Data Source
AI summary
A system and method for forming a porous ceramic preform is provided. The method may include forming a stacked powder structure including a binder layer and a powder layer on the binder layer. The binder layer may be formed by depositing a binder with a spray nozzle on a substrate. The powder layer may be formed by depositing a powder on the binder layer. The porous ceramic preform may be formed by heating the stacked powder structure to pyrolyze the binder. The porous ceramic preform is configured to be infiltrated by a molten material. The substrate may comprise a ceramic fiber preform. After melt infiltration of the porous ceramic preform and the ceramic fiber preform, a densified ceramic feature having a predetermined geometry may be formed on a ceramic matrix composite (CMC) component.