Undulating Ceramic Matrix Composite for Multi-Directional Load
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Solution Overview
Problem
Ceramic matrix composites (CMCs) are unsuitable for applications requiring loading in multiple directions due to their directional damage tolerance properties, which can lead to failure when subjected to perpendicular loads, especially in high-temperature environments, as they rely heavily on interlaminar joints that can be overloaded.
Innovation Solution
The development of a ceramic matrix composite with undulating ceramic fibre layers that extend between opposing outer surfaces, allowing load sharing between multiple layers, thereby distributing tension and shear forces and inhibiting crack propagation, along with a method of manufacturing that involves interspersing a binder material throughout the layers and applying an undulating pattern during sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional planar fibre layers are used, then manufacturing is simple, but load-bearing capability in multiple directions is poor
Solution Approach 1:
The patent applies dimensionality change by transitioning from planar (2D) fibre layers to undulating (3D) fibre layers. The fibre layers are configured to undulate between opposing outer surfaces of the article, creating a three-dimensional architecture that enables load distribution across multiple layers in perpendicular directions, thereby improving multi-directional load-bearing capability while maintaining a relatively simple layered manufacturing approach.
2Strength
If 2.5D or 3D weaving techniques are used to provide fibres bridging laminae, then load-bearing capability improves, but manufacturing complexity increases and range of component shapes is limited
Solution Approach 1:
The patent applies segmentation by dividing the fibre reinforcement into multiple discrete layers that undulate independently between opposing outer surfaces. Rather than using complex 2.5D or 3D weaving techniques that create interconnected fibre architectures, the invention uses separate undulating layers that collectively provide bridging functionality, simplifying manufacturing while achieving improved interlaminar tensile strength.
3Reliability
If load is applied perpendicular to fibre layers, then interlaminar joint failure occurs, but redistributing load requires design changes that impact assembly compatibility
Solution Approach 1:
The patent applies dimensionality change to resolve the load distribution problem. By configuring fibre layers to undulate between opposing outer surfaces, the structure naturally distributes perpendicular loads across multiple layers through the undulating geometry, improving damage tolerance without requiring complex design redistributions that would impact assembly compatibility.
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 enhances the load-bearing capabilities of CMCs, making them suitable for applications with complex loading conditions by ensuring that any load, including thermal loads, is distributed across multiple layers, reducing the risk of failure and improving their tensile strength and damage tolerance.
Implementation Method 1
For sintered CMCs, a matrix material binds the layered fibre structure both during forming and also after sintering
Data Source
AI summary
The invention concerns an article (20) formed of a ceramic matrix composite structure having a plurality of ceramic fiber layers (22) and a binder material (24) interspersed throughout said layers. The ceramic matrix composite material may be sintered. The ceramic fiber layers undulate relative to one or more outer surfaces (38;40) of the article. Thus support features (48) within the article are able to share a load in use between a plurality of layers. The invention may be suited to engine components such as turbine seal segments in a gas turbine engine.