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

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

OSTI Identifier:: 1360965

Assignee:: General Electric Company NETL

Patent Number(s):: 9,663,404

Application Number:: 13/342,498

Contract Number:: FC26-05NT42643

Resource Relation:: Patent File Date: 2012 Jan 03

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

Sponsoring Org:: USDOE

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

Full Text
View Full Text

Other works cited in this record:

Safety Device for Elevators
patent, July 1895

Kidder, Wellington P.
US Patent Document 543,153
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F0543153

Composite ceramic gas turbine blade
patent, August 1981

Rossman, Axel; Hoffmuller, Wilhelm; Kruger, Wolfgang
US Patent Document 4,285,634
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F4285634

Integral structure and thermal protection system
patent, October 1992

Scott, Harry
US Patent Document 5,154,373
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F5154373

Hollow composite turbine blade
patent, April 1995

Goetze, Raymond
US Patent Document 5,403,153
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F5403153

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

Weaver, Samuel
US Patent Document 5,573,985
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F5573985

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

Daws, David
US Patent Document 5,582,784
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F5582784

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

Atmur, Steven; Strasser, Thomas
US Patent Document 5,632,320
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F5632320

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

Rossmann, Axel; Smarsly, Wilfried
US Patent Document 5,634,189
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F5634189

Ceramic catalytic converter
patent, March 1999

Atmur, Steven; Strasser, Thomas
US Patent Document 5,879,640
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F5879640

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

Austin, Curtiss; Grylls, Richard
US Patent Document 6,428,280
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6428280

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

Schell, Jerry; Austin, Curtiss; Grylls, Richard
US Patent Document 6,435,824
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6435824

Method of manufacturing a ceramic matrix composite
patent, December 2002

Butler, Edwin; Razzell, Anthony; Dominy, John
US Patent Document 6,497,776
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6497776

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

Grylls, Richard; Austin, Curtiss; Kightlinger, James
US Patent Document 6,544,003
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6544003

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

Grylls, Richard; Austin, Curtiss; Linko, Peter
US Patent Document 6,648,596
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6648596

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

DiChiara, Robert; French, Robert; Thatcher, Conley
US Patent Document 6,676,077
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6676077

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

Withers, James; Loutfy, Raouf; Pickard, Sion
US Patent Document 6,723,279
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6723279

Thermal barrier coating
patent, May 2004

Schaeffer, Jon; Bruce, Robert
US Patent Document 6,730,413
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6730413

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

Grylls, Richard; Austin, Curtiss; Schell, Jerry
US Patent Document 6,755,619
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6755619

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

Torigoe, Taiji; Aoki, Sunao; Mori, Kazutaka
US Patent Document 6,916,551
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F6916551

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

Thebault, Jacques; David, Laurent
US Patent Document 7,063,886
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7063886

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

Bosselmann, Thomas; Willsch, Michael; Perez, Francisco
US Patent Document 7,083,384
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7083384

Investment casting
patent, December 2006

Marcin, John
US Patent Document 7,144,220
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7144220

Turbine blade for extreme temperature conditions
patent, March 2007

Jackson, Melvin; Subramanian, Pazhayannur; Zhao, Ji-Cheng
US Patent Document 7,189,459
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7189459

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

Spitsberg, Irene; Venkataramani, Venkat; Boutwell, Brett
US Patent Document 7,309,530
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7309530

Airfoil support
patent, August 2008

Matheny, Alfred
US Patent Document 7,410,342
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7410342

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

Subramanian, Suresh; Steibel, James; Carper, Douglas
US Patent Document 7,597,838
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7597838

CMC articles having small complex features
patent, October 2009

Steibel, James; Carper, Douglas; Subramanian, Suresh
US Patent Document 7,600,979
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7600979

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

Torigoe, Taiji; Mori, Kazutaka; Okada, Ikuo
US Patent Document 7,655,326
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7655326

Turbine bucket tip cap
patent, November 2010

Bunker, Ronald; Itzel, Gary
US Patent Document 7,837,440
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F7837440

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

Corman, Gregory; McGuigan, Henry; Brun, Milivoj
US Patent Document 8,043,720
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F8043720

Gas turbine shroud support apparatus
patent, November 2011

Bruce, Kevin; Cairo, Ronald; Nimmer, Ronald
US Patent Document 8,047,773
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F8047773

Coated turbine blade
patent, December 2011

Ahmad, Fathi; Dankert, Michael
US Patent Document 8,075,279
URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect2=PTO1&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&d=PALL&RefSrch=yes&Query=PN%2F8075279

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

Mack, Julia; Davis, Janet
US Patent Application 11/438387; 20070275177
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220070275177%22.PGNR.&OS=DN/20070275177&RS=DN/20070275177

Heat-Managing Composite Structures
patent-application, September 2010

Wadley, Haydn; Queheillalt, Douglas
US Patent Application 12/596548; 20100236759
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220100236759%22.PGNR.&OS=DN/20100236759&RS=DN/20100236759

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

Noe, Mark; Marusko, Mark; Jamision, Joshua
US Patent Application 12/347050; 20110027098
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220110027098%22.PGNR.&OS=DN/20110027098&RS=DN/20110027098

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

Gallagher, Michael; House, Keith; Jennings, Douglas
US Patent Application 12/915928; 20120102706
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220120102706%22.PGNR.&OS=DN/20120102706&RS=DN/20120102706

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

Del-Gallo, Pascal; Gray, Daniel
US Patent Application 13/389537; 20120142526
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220120142526%22.PGNR.&OS=DN/20120142526&RS=DN/20120142526

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

Diego, Peter de
US Patent Application 13/252540; 20130084189
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220130084189%22.PGNR.&OS=DN/20130084189&RS=DN/20130084189

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

Roberts, Herbert; Garcia-Crespo, Andres Jose; Taxacher, Glenn
US Patent Application 13/644847; 20140099484
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140099484%22.PGNR.&OS=DN/20140099484&RS=DN/20140099484

Cooled Ceramic Matrix Composite Airfoil
patent-application, September 2014

Uskert, Richard; Sippel, Aaron
US Patent Application 14/097844; 20140271153
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140271153%22.PGNR.&OS=DN/20140271153&RS=DN/20140271153

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

Brzek, Brian; Morgan, Victor; Lacy, Benjamin
US Patent Application 13/853556; 20140321994
URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PG01&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.html&r=1&f=G&l=50&s1=%2220140321994%22.PGNR.&OS=DN/20140321994&RS=DN/20140321994

Similar records in DOepatents and OSTI.GOV collections:

Pre-form ceramic matrix composite cavity and method of forming and method of forming a ceramic matrix composite component

Patent Monaghan, Philip Harold ; Delvaux, John McConnell ; Taxacher, Glenn Curtis

A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.
Full Text Available June 2015
Pre-form ceramic matrix composite cavity and a ceramic matrix composite component

Patent Monaghan, Philip Harold ; Delvaux, John McConnell ; Taxacher, Glenn Curtis

A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.
Full Text Available May 2018
Method of forming a dense, high temperature electronically conductive composite layer on a porous ceramic substrate

Patent Isenberg, Arnold O.

An electrochemical device, containing a solid oxide electrolyte material and an electrically conductive composite layer, has the composite layer attached by: (A) applying a layer of LaCrO.sub.3, YCrO.sub.3 or LaMnO.sub.3 particles (32), on a portion of a porous ceramic substrate (30), (B) heating to sinter bond the particles to the substrate, (C) depositing a dense filler structure (34) between the doped particles (32), (D) shaving off the top of the particles, and (E) applying an electronically conductive layer over the particles (32) as a contact.
Full Text Available January 1992
Metal matrix composite of an iron aluminide and ceramic particles and method thereof

Patent Schneibel, Joachim H.

A metal matrix composite comprising an iron aluminide binder phase and a ceramic particulate phase such as titanium diboride, zirconium diboride, titanium carbide and tungsten carbide is made by heating a mixture of iron aluminide powder and particulates of one of the ceramics such as titanium diboride, zirconium diboride, titanium carbide and tungsten carbide in a alumina crucible at about 1450.degree. C. for about 15 minutes in an evacuated furnace and cooling the mixture to room temperature. The ceramic particulates comprise greater than 40 volume percent to about 99 volume percent of the metal matrix composite.
Full Text Available January 1997
Method of producing an internal cavity in a ceramic matrix composite

Patent Gray, Paul Edward ; Roberts, III, Herbert Chidsey ; Taxacher, Glenn Curtis ; Walker, Sheena Kum Foster

A process for producing an internal cavity in a CMC article and mandrels used therewith. The process entails incorporating a mandrel made of a fusible material that is melted and drained during a thermal treatment of a CMC preform to form the CMC article. The mandrel material is preferably non-wetting and non-reactive with any constituents of the CMC preform during the thermal treatment. The mandrel is preferably tin or an alloy of tin.
Full Text Available July 2018