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公开(公告)号：US20220169574A1
公开(公告)日：2022-06-02
申请号：US17412686
申请日：2021-08-26
发明人： Sungbo Shim , Pathikumar Sellappan
IPC分类号： C04B35/80 , C04B35/657 , C04B35/628 , C04B35/626 , F01D5/28 , F01D25/00
摘要： A method to form a machinable ceramic matrix composite comprises forming a porous ceramic multilayer on a surface of a fiber preform. In one example, the porous ceramic multilayer comprises a gradient in porosity in a direction normal to the surface. In another example, the porous ceramic multilayer includes low-wettability particles having a high contact angle with molten silicon, where an amount of the low-wettability particles in the porous ceramic multilayer varies in a direction normal to the surface. After forming the porous ceramic multilayer, the fiber preform is infiltrated with a melt, and the melt is cooled to form a ceramic matrix composite with a surface coating thereon. An outer portion of the surface coating is more readily machinable than an inner portion of the surface coating. The outer portion of the surface coating is machined to form a ceramic matrix composite having a machined surface with a predetermined surface finish and/or dimensional tolerance.
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公开(公告)号：US20210069931A1
公开(公告)日：2021-03-11
申请号：US17015840
申请日：2020-09-09
发明人： Pathikumar Sellappan , Sungbo Shim
摘要： Methods of reducing dry crack formation in ceramic matrix composite green bodies are provided. Some of the methods expose the green body to a gaseous atmosphere at a relatively high humidity for a first period, and then slowly lower the humidity over a second period, where the gaseous atmosphere is at room temperature for both periods. Other methods start the gaseous atmosphere at room temperature and then raise the temperature to a higher temperature while the humidity is relatively high, and hold that temperature even as the humidity is lowered in the second period.
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公开(公告)号：US20210032172A1
公开(公告)日：2021-02-04
申请号：US16524397
申请日：2019-07-29
发明人： Sungbo Shim , Pathikumar Sellappan
摘要： A method to produce a protective surface layer having a predetermined topography on a ceramic matrix composite is described. The method includes applying a slurry layer to a surface of a fiber preform, and drying the slurry layer to form a particulate layer. A surface of the particulate layer is machined to improve surface smoothness and to form a machined surface. A ceramic tape is attached to the machined surface, and a tool comprising one or more features to be imprinted is placed on the ceramic tape, thereby forming a compression assembly. Heat and pressure are applied to the compression assembly to consolidate and bond the ceramic tape to the machined surface, while the one or more features of the tool are imprinted. Thus, a protective surface layer having a predetermined topography is formed.
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公开(公告)号：US12071380B2
公开(公告)日：2024-08-27
申请号：US17412686
申请日：2021-08-26
发明人： Sungbo Shim , Pathikumar Sellappan
IPC分类号： C04B35/80 , C04B35/626 , C04B35/628 , C04B35/657 , F01D5/28 , F01D25/00
CPC分类号： C04B35/80 , C04B35/62655 , C04B35/62863 , C04B35/62886 , C04B35/62894 , C04B35/657 , F01D5/284 , F01D25/005 , C04B2235/3418 , C04B2235/3826 , C04B2235/386 , C04B2235/3865 , C04B2235/5244 , C04B2235/5252 , C04B2235/612 , C04B2235/616 , C04B2235/9669
摘要： A method to form a machinable ceramic matrix composite comprises forming a porous ceramic multilayer on a surface of a fiber preform. In one example, the porous ceramic multilayer comprises a gradient in porosity in a direction normal to the surface. In another example, the porous ceramic multilayer includes low-wettability particles having a high contact angle with molten silicon, where an amount of the low-wettability particles in the porous ceramic multilayer varies in a direction normal to the surface. After forming the porous ceramic multilayer, the fiber preform is infiltrated with a melt, and the melt is cooled to form a ceramic matrix composite with a surface coating thereon. An outer portion of the surface coating is more readily machinable than an inner portion of the surface coating. The outer portion of the surface coating is machined to form a ceramic matrix composite having a machined surface with a predetermined surface finish and/or dimensional tolerance.
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公开(公告)号：US20210147303A1
公开(公告)日：2021-05-20
申请号：US17088897
申请日：2020-11-04
IPC分类号： C04B35/80 , C04B35/628 , C04B35/657
摘要： A method of producing a CMC component that includes forming a preform having a plurality of ceramic fiber plies with each ply occupying a predetermined position; rigidizing the preform with a fiber interphase coating; inspecting the preform to determine which of the plies has partially or fully delaminated; reworking the delaminated plies in the preform; infiltrating a ceramic slurry into the preform to form a green body; optionally, conducting a secondary operation on the green body; and infiltrating the green body with a molten silicon or silicon alloy to form the CMC component. The step of reworking delaminated plies may also be applied to a green body formed after ceramic slurry infiltration into a rigidized fiber preform.
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公开(公告)号：US11858862B1
公开(公告)日：2024-01-02
申请号：US17871401
申请日：2022-07-22
IPC分类号： C04B35/80 , C04B35/657 , C04B35/628
CPC分类号： C04B35/80 , C04B35/62884 , C04B35/62892 , C04B35/62894 , C04B35/62897 , C04B35/657 , C04B2235/5252 , C04B2235/612 , C04B2235/616
摘要： A method to produce a ceramic matrix composite part, wherein the method comprises providing a ceramic fiber preform. Wherein the ceramic fiber preform includes a three-dimensional framework of a plurality of ceramic fibers. The method comprising, prior to melt infiltration, adding a layer of machinable stock to a target area of the ceramic fiber preform, melt infiltrating the ceramic fiber preform, forming the ceramic matrix composite part by cooling the melt infiltrated ceramic fiber preform, and machining the part in the target area where the machinable stock is located.
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公开(公告)号：US20210070664A1
公开(公告)日：2021-03-11
申请号：US17012977
申请日：2020-09-04
IPC分类号： C04B35/80 , B28B11/04 , F01D25/08 , C04B35/628 , C04B35/657 , C04B41/00 , C04B41/50 , C04B41/87
摘要： A method is provided in which a resin coating is applied to a surface of a preform. The resin coating includes a carbonaceous resin and a particulate. The preform is added to a tooling. The preform, which is positioned in the tooling, is cured. The tooling is removed. The resin coating on the surface of the preform is pyrolyzed to form a resin carbon-char layer on the surface of the preform. The preform and the resin carbon-char layer are infiltrated with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide. During the infiltration, the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform.
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公开(公告)号：US20230192564A1
公开(公告)日：2023-06-22
申请号：US17559277
申请日：2021-12-22
IPC分类号： C04B37/00
CPC分类号： C04B37/003 , C04B2237/09 , C04B2237/38 , C04B2237/60 , C04B2237/083 , C04B2237/84
摘要： In some examples, a method including forming a layer of a slurry composition between a first ceramic or CMC part and a second ceramic or CMC part. The slurry composition includes a carrier material; and a plurality of solid particles in the carrier material. The plurality of solid particles includes first silicon carbide (SiC) particles defining a first average particle size, second SiC particles defining a second average particles size that is less than the first average particles size, and reactive additive particles. The method includes heating the layer of slurry composition to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles, wherein the fused layer of the slurry composition forms a joint layer that joins the first ceramic or CMC part to the second ceramic or CMC part.
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公开(公告)号：US11667580B2
公开(公告)日：2023-06-06
申请号：US17012977
申请日：2020-09-04
IPC分类号： C04B35/80 , F01D25/08 , C04B35/628 , C04B35/657 , C04B41/00 , C04B41/50 , C04B41/87 , B28B11/04
CPC分类号： C04B35/80 , B28B11/041 , C04B35/62863 , C04B35/62873 , C04B35/657 , C04B41/009 , C04B41/5059 , C04B41/87 , F01D25/08 , C04B2235/3826 , C04B2235/48 , C04B2235/5252 , C04B2235/616 , F05D2220/32 , F05D2230/20 , F05D2230/90
摘要： A method is provided in which a resin coating is applied to a surface of a preform. The resin coating includes a carbonaceous resin and a particulate. The preform is added to a tooling. The preform, which is positioned in the tooling, is cured. The tooling is removed. The resin coating on the surface of the preform is pyrolyzed to form a resin carbon-char layer on the surface of the preform. The preform and the resin carbon-char layer are infiltrated with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide. During the infiltration, the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform.
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10.发明授权公开(公告)号：US11186525B2
公开(公告)日：2021-11-30
申请号：US16524397
申请日：2019-07-29
发明人： Sungbo Shim , Pathikumar Sellappan
IPC分类号： C04B41/87 , C04B41/50 , C04B41/45 , C04B35/83 , C04B35/645
摘要： A method to produce a protective surface layer having a predetermined topography on a ceramic matrix composite is described. The method includes applying a slurry layer to a surface of a fiber preform, and drying the slurry layer to form a particulate layer. A surface of the particulate layer is machined to improve surface smoothness and to form a machined surface. A ceramic tape is attached to the machined surface, and a tool comprising one or more features to be imprinted is placed on the ceramic tape, thereby forming a compression assembly. Heat and pressure are applied to the compression assembly to consolidate and bond the ceramic tape to the machined surface, while the one or more features of the tool are imprinted. Thus, a protective surface layer having a predetermined topography is formed.
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