Method of forming a ceramic matrix composite and a ceramic matrix component

Title: Method of forming a ceramic matrix composite and a ceramic matrix component

Abstract

A method of forming a ceramic matrix composite component includes providing a formed ceramic member having a cavity, filling at least a portion of the cavity with a ceramic foam. The ceramic foam is deposited on a barrier layer covering at least one internal passage of the cavity. The method includes processing the formed ceramic member and ceramic foam to obtain a ceramic matrix composite component. Also provided is a method of forming a ceramic matrix composite blade and a ceramic matrix composite component.

Inventors:: de Diego, Peter; Zhang, James

Issue Date:: 2017-05-30

Research Org.:: General Electric Co., Schenectady, NY (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1360965

Patent Number(s):: 9663404

Application Number:: 13/342,498

Assignee:: General Electric Company

Patent Classifications (CPCs):: C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

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C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/481 - {containing silicon, e.g. zircon}
C04B35/14 - based on silica
C04B2235/3244 - Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
C04B2235/80 - Phases present in the sintered or melt-cast ceramic products other than the main phase

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
Y10T428/24694 - Parallel corrugations

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/488 - Composites
C04B2235/3463 - Alumino-silicates other than clay, e.g. mullite
C04B2235/3217 - Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
Y10T428/249981 - Plural void-containing components

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/653 - Processes involving a melting step
C04B2235/3248 - Zirconates or hafnates, e.g. zircon

F - MECHANICAL ENGINEERING F01 - MACHINES OR ENGINES IN GENERAL F01D - NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
F01D5/20 - Specially-shaped blade tips to seal space between tips and stator {

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/117 - Composites
C04B2235/3804 - Borides
C04B35/5805 - {based on borides}
C04B35/52 - based on carbon, e.g. graphite

F - MECHANICAL ENGINEERING F01 - MACHINES OR ENGINES IN GENERAL F01D - NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
F01D5/284 - {Selection of ceramic materials}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B2235/616 - Liquid infiltration of green bodies or pre-forms
C04B2235/3418 - Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
C04B35/185 - Mullite {3Al2O3-2SiO2}
C04B2235/422 - Carbon

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DOE Contract Number:: FC26-05NT42643

Resource Type:: Patent

Resource Relation:: Patent File Date: 2012 Jan 03

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

Citation Formats


                    de Diego, Peter, and Zhang, James. Method of forming a ceramic matrix composite and a ceramic matrix component.  United States: N. p., 2017. 
        Web.

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                    de Diego, Peter, & Zhang, James. Method of forming a ceramic matrix composite and a ceramic matrix component.  United States.

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                    de Diego, Peter, and Zhang, James. Tue .  
        "Method of forming a ceramic matrix composite and a ceramic matrix component".  United States.  https://www.osti.gov/servlets/purl/1360965.

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@article{osti_1360965,

  title        = {Method of forming a ceramic matrix composite and a ceramic matrix component},

  author       = {de Diego, Peter and Zhang, James},

  abstractNote = {A method of forming a ceramic matrix composite component includes providing a formed ceramic member having a cavity, filling at least a portion of the cavity with a ceramic foam. The ceramic foam is deposited on a barrier layer covering at least one internal passage of the cavity. The method includes processing the formed ceramic member and ceramic foam to obtain a ceramic matrix composite component. Also provided is a method of forming a ceramic matrix composite blade and a ceramic matrix composite component.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2017},

  month        = {5}

}

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Title: Method of forming a ceramic matrix composite and a ceramic matrix component

Abstract

Citation Formats

Safety Device for Elevators patent, July 1895

Thermally Insulated Composite Article patent, January 1973

Composite ceramic gas turbine blade patent, August 1981

Integral structure and thermal protection system patent, October 1992

Hollow composite turbine blade patent, April 1995

Ceramic matrix composites using strengthening agents of silicon borides of the form Si-B-C patent, November 1996

Method of making ceramic matrix composite/ceramic foam panels patent, December 1996

Methods and apparatus for making ceramic matrix composite lined automotive parts and fiber reinforced ceramic matrix composite automotive parts patent, May 1997

Structural component made of metal or ceramic having a solid outer shell and a porous core and its method of manufacture patent, May 1997

Exhaust manifold with integral catalytic converter patent, December 1997

Ceramic catalytic converter patent, March 1999

Structure with ceramic foam thermal barrier coating, and its preparation patent, August 2002

Gas turbine stationary shroud made of a ceramic foam material, and its preparation patent, August 2002

Method of manufacturing a ceramic matrix composite patent, December 2002

Gas turbine blisk with ceramic foam blades and its preparation patent, April 2003

Turbine blade or turbine vane made of a ceramic foam joined to a metallic nonfoam, and preparation thereof patent, November 2003

High temperature resistant airfoil apparatus for a hypersonic space vehicle patent, January 2004

Golf club and other structures, and novel methods for making such structures patent, April 2004

Thermal barrier coating patent, May 2004

Turbine blade with ceramic foam blade tip seal, and its preparation patent, June 2004

Thermal barrier coating material, gas turbine parts and gas turbine patent, July 2005

Thermostructural composite structure with a compositional gradient and its manufacturing process patent, June 2006

Doppler radar sensing system for monitoring turbine generator components patent, August 2006

Investment casting patent, December 2006

Turbine blade for extreme temperature conditions patent, March 2007

Thermal barrier coating with reduced sintering and increased impact resistance, and process of making same patent, December 2007

Thermal barrier coating system method of manufacturing the same patent, April 2008

Airfoil support patent, August 2008

Functionally gradient SiC/SiC ceramic matrix composites with tailored properties for turbine engine applications patent, October 2009

CMC articles having small complex features patent, October 2009

Thermal barrier coating material and method for production thereof, gas turbine member using the thermal barrier coating material, and gas turbine patent, February 2010

Turbine bucket tip cap patent, November 2010

Process of producing a ceramic matrix composite article and article formed thereby patent, October 2011

Gas turbine shroud support apparatus patent, November 2011

Coated turbine blade patent, December 2011

Ceramic oxide pre-forms, metal matrix composites, and methods for making the same patent-application, June 2002

High temperature resistant airfoil apparatus for a hypersonic space vehicle patent-application, March 2004

Integrated ceramic/metallic components and methods of making same patent-application, November 2005

Ceramic foam-filled sandwich panels and method patent-application, November 2007

Composite Structures having Reinforced Edge Bonded Joints and Method for Making the Same patent-application, January 2009

Foamed Tools patent-application, April 2010

Heat-Managing Composite Structures patent-application, September 2010

Ceramic Matrix Composite Blade Having Integral Platform Structures And Methods Of Fabrication patent-application, February 2011

Methods of Making Filter Apparatus and Fabricating a Porous Ceramic Article patent-application, May 2012

Method For Producing A Ceramic Foam Having Reinforced Mechanical Strength For Use As A Substrate For A Catalyst Bed patent-application, June 2012

Annulus Filler System patent-application, October 2012

Cmc Component, Power Generation System And Method Of Forming A Cmc Component patent-application, April 2013

Hot Gas Path Component for Turbine System patent-application, April 2013

Ceramic Matrix Composite, Method Of Making A Ceramic Matrix Composite, And A Pre-Preg Composite Ply patent-application, April 2014

Cooled Ceramic Matrix Composite Airfoil patent-application, September 2014

Hot Gas Path Component For Turbine System patent-application, October 2014

Composite Blades for Gas Turbine Engines patent-application, May 2016

Safety Device for Elevators
patent, July 1895

Thermally Insulated Composite Article
patent, January 1973

Composite ceramic gas turbine blade
patent, August 1981

Integral structure and thermal protection system
patent, October 1992

Hollow composite turbine blade
patent, April 1995

Ceramic matrix composites using strengthening agents of silicon borides of the form Si-B-C
patent, November 1996

Method of making ceramic matrix composite/ceramic foam panels
patent, December 1996

Methods and apparatus for making ceramic matrix composite lined automotive parts and fiber reinforced ceramic matrix composite automotive parts
patent, May 1997

Structural component made of metal or ceramic having a solid outer shell and a porous core and its method of manufacture
patent, May 1997

Exhaust manifold with integral catalytic converter
patent, December 1997

Ceramic catalytic converter
patent, March 1999

Structure with ceramic foam thermal barrier coating, and its preparation
patent, August 2002

Gas turbine stationary shroud made of a ceramic foam material, and its preparation
patent, August 2002

Method of manufacturing a ceramic matrix composite
patent, December 2002

Gas turbine blisk with ceramic foam blades and its preparation
patent, April 2003

Turbine blade or turbine vane made of a ceramic foam joined to a metallic nonfoam, and preparation thereof
patent, November 2003

High temperature resistant airfoil apparatus for a hypersonic space vehicle
patent, January 2004

Golf club and other structures, and novel methods for making such structures
patent, April 2004

Thermal barrier coating
patent, May 2004

Turbine blade with ceramic foam blade tip seal, and its preparation
patent, June 2004

Thermal barrier coating material, gas turbine parts and gas turbine
patent, July 2005

Thermostructural composite structure with a compositional gradient and its manufacturing process
patent, June 2006

Doppler radar sensing system for monitoring turbine generator components
patent, August 2006

Investment casting
patent, December 2006

Turbine blade for extreme temperature conditions
patent, March 2007

Thermal barrier coating with reduced sintering and increased impact resistance, and process of making same
patent, December 2007

Thermal barrier coating system method of manufacturing the same
patent, April 2008

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patent, August 2008

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patent, October 2009

CMC articles having small complex features
patent, October 2009

Thermal barrier coating material and method for production thereof, gas turbine member using the thermal barrier coating material, and gas turbine
patent, February 2010

Turbine bucket tip cap
patent, November 2010

Process of producing a ceramic matrix composite article and article formed thereby
patent, October 2011

Gas turbine shroud support apparatus
patent, November 2011

Coated turbine blade
patent, December 2011

Ceramic oxide pre-forms, metal matrix composites, and methods for making the same
patent-application, June 2002

High temperature resistant airfoil apparatus for a hypersonic space vehicle
patent-application, March 2004

Integrated ceramic/metallic components and methods of making same
patent-application, November 2005

Ceramic foam-filled sandwich panels and method
patent-application, November 2007

Composite Structures having Reinforced Edge Bonded Joints and Method for Making the Same
patent-application, January 2009

Foamed Tools
patent-application, April 2010

Heat-Managing Composite Structures
patent-application, September 2010

Ceramic Matrix Composite Blade Having Integral Platform Structures And Methods Of Fabrication
patent-application, February 2011

Methods of Making Filter Apparatus and Fabricating a Porous Ceramic Article
patent-application, May 2012

Method For Producing A Ceramic Foam Having Reinforced Mechanical Strength For Use As A Substrate For A Catalyst Bed
patent-application, June 2012

Annulus Filler System
patent-application, October 2012

Cmc Component, Power Generation System And Method Of Forming A Cmc Component
patent-application, April 2013

Hot Gas Path Component for Turbine System
patent-application, April 2013

Ceramic Matrix Composite, Method Of Making A Ceramic Matrix Composite, And A Pre-Preg Composite Ply
patent-application, April 2014

Cooled Ceramic Matrix Composite Airfoil
patent-application, September 2014

Hot Gas Path Component For Turbine System
patent-application, October 2014

Composite Blades for Gas Turbine Engines
patent-application, May 2016