U.S. patent application number 14/320295 was filed with the patent office on 2014-10-23 for ceramic composite components.
The applicant listed for this patent is General Electric Company. Invention is credited to Paul Stephen DiMascio, Herbert Chidsey Roberts.
Application Number | 20140315001 14/320295 |
Document ID | / |
Family ID | 43971343 |
Filed Date | 2014-10-23 |
United States Patent
Application |
20140315001 |
Kind Code |
A1 |
Roberts; Herbert Chidsey ;
et al. |
October 23, 2014 |
CERAMIC COMPOSITE COMPONENTS
Abstract
A method for fabricating a ceramic composite includes forming a
first ceramic composite layer (CCL), positioning a form against the
first CCL, positioning a second CCL against the form such that the
form is at least partially circumscribed by the first CCL and the
second CCL. The method also includes coupling the first CCL to the
second CCL, such that at least a first passage extends in a first
direction across at least a portion of the ceramic composite
component and is defined at least partially by the first CCL and
the second CCL in a location vacated by the first form.
Inventors: |
Roberts; Herbert Chidsey;
(Middletown, OH) ; DiMascio; Paul Stephen; (Greer,
SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
43971343 |
Appl. No.: |
14/320295 |
Filed: |
June 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12761932 |
Apr 16, 2010 |
8801886 |
|
|
14320295 |
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Current U.S.
Class: |
428/188 |
Current CPC
Class: |
C04B 2237/32 20130101;
Y10T 428/24744 20150115; C04B 37/008 20130101; C04B 35/632
20130101; Y10T 428/24612 20150115; F01D 25/12 20130101; F01D 25/005
20130101; B32B 18/00 20130101; F05C 2203/08 20130101; C04B 2237/62
20130101; C04B 35/653 20130101; C04B 35/63476 20130101; Y10T 156/10
20150115; F05C 2253/04 20130101 |
Class at
Publication: |
428/188 |
International
Class: |
F01D 25/12 20060101
F01D025/12; F01D 25/00 20060101 F01D025/00 |
Claims
1-15. (canceled)
16. A ceramic composite component comprising: a body extending from
an upper surface to a lower surface, said body comprising: a first
ceramic composite layer (CCL); and a second CCL positioned against
said first CCL such that first sides of said first and second CCLs
define exterior surfaces of the ceramic composite component,
wherein said first and second CCLs at least partially define a
first passage extending in a first direction between said first and
second CCLs and a second passage extending perpendicular from the
first passage, such that the second passage does not extend to an
outer edge of said body.
17. The component in accordance with claim 16 wherein the first and
second passages are defined at least partially by the first and
second CCLs in locations vacated by a first form and a second
form.
18. The component in accordance with claim 16 wherein the first
passage extends at least one of obliquely or orthogonally from the
second passage.
19. The component in accordance with claim 16 wherein said first
and second CCLs are bonded together by a heat curing process.
20. The component in accordance with claim 16 further comprising a
third CCL between said first and second CCLs.
21. The component in accordance with claim 17, wherein said first
and second CCLs each comprise second sides having a shape that is
substantially complementary to a shape of said first and second
forms.
22. A gas turbine engine component comprising: a body extending
from an upper surface to a lower surface, said body comprising: a
first ceramic composite layer (CCL); a second CCL positioned
against said first CCL such that first sides of said first and
second CCLs define the upper and lower surfaces of the ceramic
composite component, wherein said first and second CCLs at least
partially define a first passage extending in a first direction
between said first and second CCLs and a second passage extending
perpendicular from the first passage, such that the second passage
does not extend to an outer edge of said body; and a third CCL
extending between said first and second CCLs, wherein said third
CCL extends across said body such that said third CCL is positioned
on opposing sides of said first and second passages.
23. The component in accordance with claim 22 wherein said first
and second passages are defined at least partially by the first and
second CCLs in locations vacated by a first form and a second
form.
24. The component in accordance with claim 23, wherein said first
and second CCLs include second sides that at least partially define
a shape that is substantially complementary to a shape of said
first and second forms.
25. The component in accordance with claim 22 wherein said first
passage extends at least one of obliquely or orthogonally from said
second passage.
26. The component in accordance with claim 22 wherein said first,
second, and third CCLs are bonded together by a heat curing
process.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional and claims priority to U.S.
patent application Ser. No. 12/761,932 filed Apr. 16, 2010 for
"CERAMIC COMPOSITE COMPONENTS AND METHODS OF FABRICATING THE SAME",
which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The field of the invention relates generally to the
manufacture of composite components and more particularly, to
ceramic composite components and methods of fabricating the
same.
[0003] Because of the heat and temperature resistivity of ceramic
materials, components fabricated from ceramic materials are often
used in lieu of components fabricated from other materials, such as
metal components. Often, ceramic components are fabricated with a
hollow cavity or flow passage defined therein that enables cooling
fluid to be channeled through the components to facilitate cooling,
or other transfer of energy, to the components and/or components
downstream from the ceramic components. For example, at least some
known gas turbine engines include components that may be at least
partially manufactured from a composite material. Such turbine
components may be at least partially cooled by a film of cooling
air discharged from a cavity defined in the component.
[0004] At least one known method of fabricating ceramic components
involves a casting process in which multiple cooling slots are
formed in the components in a plurality of substantially parallel
rows. For example, in known components, each of the slots created
in the component is formed with one or more lengths when the
component is fabricated using a lost wax or investment casting
process. During such a casting process, an insert is used to create
the component. While such a process is commonly used with
non-ceramic components, manufacturing ceramic components with such
a casting process may be difficult, time-consuming, and
expensive.
[0005] Another known method of fabricating composite components is
a layering method of fabrication. In such a method, several layers
of ceramic materials may be coupled together such that passages may
be later formed using a drill or other forms of energy to
systematically remove existing material. However, because of the
strength of the materials used in fabricating such components,
drill bits, or other forms of energy transfer devices and systems,
may prematurely wear out, thus increasing the cost of fabrication.
Moreover, in such a fabrication process, the orientation of each
passage is limited because of the inherent limitations of known
drill bits or other energy transfer devices and systems.
BRIEF DESCRIPTION OF THE INVENTION
[0006] In one aspect, a ceramic composite component is provided.
The ceramic composite component includes a body extending from an
upper surface to a lower surface, said body including a first
ceramic composite layer (CCL) and a second CCL positioned against
the first CCL such that first sides of the first and second CCLs
define exterior surfaces of the ceramic composite component. The
first and second CCLs at least partially define a first passage
extending in a first direction between the first and second CCLs
and a second passage extending perpendicular from the first
passage, such that the second passage does not extend to an outer
edge of the body.
[0007] In another aspect, a gas turbine engine component is
provided. The component includes a body extending from an upper
surface to a lower surface. The body includes a first ceramic
composite layer (CCL), a second CCL positioned against the first
CCL such that first sides of the first and second CCLs define the
upper and lower surfaces of the ceramic composite component. The
first and second CCLs at least partially define a first passage
extending in a first direction between the first and second CCLs
and a second passage extending perpendicular from the first
passage, such that the second passage does not extend to an outer
edge of said body. The component also includes a third CCL
extending between the first and second CCLs, wherein the third CCL
extends across the body such that the third CCL is positioned on
opposing sides of the first and second passages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of an exemplary ceramic
composite component, in its initial phase of fabrication, and that
is being fabricated with only two layers.
[0009] FIG. 2 is a perspective view of an alternative embodiment of
a ceramic composite component, in its initial phase of fabrication,
and that is being fabricated with more than two layers.
[0010] FIG. 3 is a perspective view of a further alternative
embodiment of a ceramic composite component, in its initial phase
of fabrication, and that is being fabricated with more than two
layers.
[0011] FIG. 4 is a perspective view of an exemplary hollow form
that may be used in fabricating a composite component, such as the
components shown in FIGS. 1-3.
[0012] FIG. 5 is a cross-sectional view of an exemplary ceramic
composite component that includes a plurality of internal passages
that are coupled together in flow communication.
[0013] FIG. 6 is a cross-sectional view of an alternative ceramic
composite component that includes a plurality of internal passages
extending in a plurality of different orientations.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 is a perspective view of an exemplary ceramic
composite component 100, in its initial phase of fabrication. In
the exemplary embodiment, component 100 is formed via processing
techniques such as those disclosed in U.S. Pat. No. 6,024,898, for
example. More specifically, in the exemplary embodiment, ceramic
component 100 is formed with a first ceramic composite layer (CCL)
110, and a second CCL 120, using a form system 130. In the
exemplary embodiment, form system 130 is hollow and includes
passage segments 150 and 160 and is hollow. Alternatively, all or
at least a portion of form system 130 can be solid.
[0015] More specifically, in the exemplary embodiment, each segment
150 and 160 has a respective substantially circular cross-sectional
shape and a substantially elliptical cross-sectional shape.
Alternatively, each segment 150 and/or 160 may have any
cross-sectional shape that enables component 100 to function as
described herein. Moreover, in the exemplary embodiment, each
passage segment 150 and 160 extends inward from at least one outer
edge 114 of CCL 110 and 120. Alternatively, at least one end of
passage segments 150 and/or 160 terminates a distance inwardly from
an outer edge 114 of layer 110 and 120 and is substantially sealed
by layers 110 and 120.
[0016] Initially, in the exemplary embodiment, first CCL 110 is
positioned on a substantially planar surface and form system 130 is
positioned against an upper surface 112 of first CCL 110.
Specifically, form system 130 is positioned in a location relative
to CCL 110 that enables passages (not shown in FIG. 1) to be formed
in desired locations within component 100. After form system 130 is
aligned in a desired orientation, a second CCL 120 is extended
across first CCL 110 and form system 130, such that form system 130
is substantially sandwiched between, and circumscribed by, layers
110 and 120. Component 100 is then heat-treated to securely bind
layers 110 and 120 together. In the exemplary embodiment, layers
110 and 120 each include a binder that facilitates enhancing the
adhesion between layers 110 and 120. For example, the binder may
be, but is not limited to being a phenolic resin or anamyl acetate
compound. Additionally, in the exemplary embodiment, form system
130 is fabricated from a non-ceramic material, such as, but not
limited to wood, plastic, or a compound of ceramic and non-ceramic
materials. In one embodiment, the use of a compound of ceramic and
non-ceramic materials may be used to add surface features,
including but not limited to, fins and swirlers to a passage that
facilitates transferring energy along the passage or through the
surface wall. Alternatively, form system 130 may be fabricated from
any material that enables system 130 to function as described
herein. During the heat-treating process, the binder and form
system 130 are each melted and dissolved from component 100, such
that a plurality of passages (not shown in FIG. 1) are defined in
those locations vacated by passage segments 150 and 160.
[0017] FIG. 2 is a perspective view of an exemplary ceramic
composite component 200, in its initial phase of fabrication. In
the exemplary embodiment, component 200 is formed with a first
ceramic composite layer (CCL) 202, a second CCL 204, a third CCL
206, and an upper CCL 208, and uses a form system 220 during the
fabrication process. More specifically, in the example embodiment,
form system 220 includes two hollow passage segments 222 and 224.
Alternatively, at least a portion of form system 220, including
segment 222 and/or segment 224, can be solid. Initially, in the
exemplary embodiment, first CCL 202 is positioned on a
substantially planar surface, and hollow form system 220 is
positioned against an upper surface 210 of first CCL 202 in a
location that enables passages (not shown in FIG. 2) to be formed
in desired locations within component 200. A second CCL 204 is
extended across first CCL 202, such that hollow form system 220 is
at least partially encapsulated between first CCL 202 and second
CCL 204. A third CCL 206 is then extended across second CCL 204
such that form system 220 is substantially encapsulated by CCLs
202, 204, and 206. An upper CCL 208 is then extended across third
CCL 206.
[0018] When CCLs 202, 204, 206, and 208 are each arranged and
aligned in their desired orientations, ceramic component 200 is
heat-treated to securely bind layers 202, 204, 206, and 208
together using a binder that facilitates enhancing the adhesion
between layers 202, 204, 206, and 208. Moreover, during the
heat-treatment, the binder and form system 220 are each melted such
that a plurality of passages are defined in locations previously
occupied by passage segments 222 and 224. In the exemplary
embodiment, passage segments 222 and/or 224 have a respective
substantially circular cross-sectional shape and a substantially
elliptical cross-sectional shape. Alternatively, each segment 222
and/or 224 may have any cross-sectional shape that enables
component 200 to function as described herein.
[0019] FIG. 3 is a perspective view of an exemplary ceramic
composite component 300, in its initial phase of fabrication. In
the exemplary embodiment, component 300 is formed from a plurality
of layers 302, 304, and 306, and uses a form system 320 during the
fabrication process. In the exemplary embodiment, form system 320
is hollow. Alternatively, any or all of form system 320 can be
solid. Moreover, in the exemplary embodiment, a first ceramic
composite layer (CCL) 302 is initially positioned on a
substantially planar surface, and form system 320 is positioned
against an upper surface 310 of first CCL 302. Moreover, in the
exemplary embodiment, form system 320 includes at least a first
passage segment 330 and a second passage segment 332. A second CCL
304 is positioned to extend between segments 330 and 332 such that
passage segments 330 and 332 are partially circumscribed by CCL
304. An upper layer 306 is then positioned across first CCL 302 and
second CCL 304 such that, in the exemplary embodiment, upper layer
306 extends across a full width W of component 300. When layers
302, 304, and 306 are arranged and aligned in their desired
orientation, ceramic component 300 is heat-treated to securely bind
layers 302, 304, and 306, together, such that form system 320 is
melted to produce a plurality of passages (not shown in FIG. 3) in
the locations within component 300 that were vacated by form system
320. In an alternative embodiment, a plurality of layers of ceramic
composite material could be positioned between segments 330 and
332.
[0020] It should be noted that ceramic components, such as
components 100, 200, and/or 300, can be fabricated with any number
of layers of ceramic composite materials and/or with the layers of
ceramic composite materials oriented in any orientation that
enables the resulting ceramic components to function as described
herein. Moreover, ceramic components, such as components 100, 200,
and/or 300, can be fabricated with any number of passages oriented
in any direction(s) that enables the resulting ceramic components
to function as described herein. A benefit of adding multiple
layers, such as layer 304, to a specified region or regions during
the fabrication process, is that the resulting ceramic components
provided can be provided with extra weight or strength in specified
regions.
[0021] FIG. 4 is a perspective view of an exemplary form system 400
that can be used in fabricating ceramic components, such as
components 100, 200, and/or 300 (shown in FIGS. 1, 2, and 3). In
the exemplary embodiment, form system 400 includes a plurality of
hollow passage segments 402 that are oriented generally parallel to
each other and that are coupled together in flow communication by a
plurality of hollow connecting segments 404. More specifically, in
the exemplary embodiment, segments 404 extend generally
perpendicularly between adjacent passage segments 402 to enable
passages created by segments 402 to be coupled together in flow
communication.
[0022] FIG. 5 is a cross-sectional view of an exemplary ceramic
composite component 500 that could be formed using the fabrication
methods described herein. In the exemplary embodiment, component
500 includes a first aperture 502, a second aperture 504, a
plurality of passages 510 oriented in a first direction, and a
plurality of passages 512 oriented in a second direction that is
substantially perpendicular to passages 510.
[0023] FIG. 6 is a cross-sectional view of an alternative ceramic
composite component 600 that could be formed using the fabrication
methods described herein. Similarly, ceramic component 600 includes
a first passage 610, a second passage 620, and passages 630 and 640
that are oriented obliquely with respect to passages 610 and 620.
In the exemplary embodiment, passage 610 extends to edge 616 and
includes an aperture 612. Passage 620 is in flow communication with
is substantially perpendicular to passage 610. Moreover, passage
620 does not extend to an outer edge 618 of component 600.
Obliquely-oriented passages 630 include apertures 632 and 634 that
enable flow communication through passages 630. Passages 630 also
include a passage 636 that extends between passages 630 to enable
flow communication between apertures 632 and 634. Passages 640 are
formed such that they are sealed within component 600.
[0024] A benefit of fabricating a ceramic component, such as
component 600 (shown in FIG. 6), using form system 400, is that
passages, such as 610 and 620, may be formed to enable
bi-directional flow communication throughout the ceramic component
while only having one aperture, such as aperture 612. In contrast,
known systems of fabricating ceramic composite components, such as
layering methods, cannot produce passages that enable
bi-directional flow communication without including apertures for
each passage because of fabrication limitations inherent with
forming passages using drills. More specifically, when using a
drill, or other forms of energy to systematically remove existing
material to create flow passages, connecting passages must each
extend from the edge of a component to a passage. As such, another
advantage of using form system 400 is the elimination of the
requirement to form passages in a composite component using a drill
or other forms of energy.
[0025] Another benefit of using form system 400 when fabricating a
ceramic component is that form system 400 enables air, fluid, or
gas to enter and exit through first aperture and continue to flow
through the entire component allowing for heating or cooling of the
component and exit a second aperture (as shown in FIGS. 5 and 6).
Another benefit of using form system 400 when fabricating a ceramic
component is that form system 400 enables the insertion of solid or
foam materials in the flow passages. Additionally, another benefit
of using form system 400 when fabricating a ceramic component is
that form system 400 can include curved segments to produce curved
flow passages (not shown) within a ceramic component.
[0026] Yet, another benefit of fabricating a ceramic component
using form system 400 is that flow passages can be created that are
sealed in a component, such as passages 640 (shown in FIG. 6). A
benefit of using sealed passages is that structural support can be
easily added to a component as a rib could be inserted into the
passages of the component. Additionally, it could be seen by one
skilled in the art that sealed flow passages could be used as a
heat pipe, or other means of energy transfer, as they are sealed in
the component.
[0027] The above-described methods and apparatus provide a
cost-effective and highly reliable method for fabricating a ceramic
composite component with internal passages. The fabrication process
described herein provides a cost effective method of fabricating
ceramic composite components that enable internal cooling passages
formed in a manner that does not sacrifice the structural integrity
of the component. In addition, the internal passages, in one
embodiment facilitate reducing the weight of the component,
facilitate reducing vibration, and provide an area in which ribs
may be inserted to enhance the structural strength of the
component. The fabrication also provides thermal growth benefits
due to its structure.
[0028] Exemplary embodiments of an apparatus and method for
fabricating a ceramic composite component are described above in
detail. The apparatus and fabrication methods are not limited to
the specific embodiments described herein. For example, the
fabrication methods need not be limited to practice with only
ceramic composite components. Rather, the present invention can be
implemented and utilized in connection with many other high
temperature component applications.
[0029] While the invention has been described in terms of various
specific embodiments, those skilled in the art will recognize that
the invention can be practiced with modification within the spirit
and scope of the claims.
* * * * *