U.S. patent application number 15/234101 was filed with the patent office on 2016-12-01 for multi-layer ceramic composite porous structure.
The applicant listed for this patent is Rolls-Royce North American Technologies, Inc.. Invention is credited to Ted Joseph Freeman, Jay Lane, David John Thomas, Richard Christopher Uskert.
Application Number | 20160348586 15/234101 |
Document ID | / |
Family ID | 46383503 |
Filed Date | 2016-12-01 |
United States Patent
Application |
20160348586 |
Kind Code |
A1 |
Uskert; Richard Christopher ;
et al. |
December 1, 2016 |
MULTI-LAYER CERAMIC COMPOSITE POROUS STRUCTURE
Abstract
An article of manufacture includes a first ceramic matrix
composite (CMC) sheet having a number of flow passages
therethrough, and a CMC foam layer bonded to the first CMC sheet.
The CMC foam layer is an open-cell foam. The article of manufacture
includes a second CMC sheet bonded to the CMC foam layer, the
second CMC sheet having a thermal and environmental barrier coating
and having a number of flow passages therethrough.
Inventors: |
Uskert; Richard Christopher;
(Monkton, MD) ; Freeman; Ted Joseph; (Avon,
IN) ; Thomas; David John; (Brownsburg, IN) ;
Lane; Jay; (Mooresville, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rolls-Royce North American Technologies, Inc. |
Indianapolis |
IN |
US |
|
|
Family ID: |
46383503 |
Appl. No.: |
15/234101 |
Filed: |
August 11, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13337106 |
Dec 24, 2011 |
9421733 |
|
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15234101 |
|
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|
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61428701 |
Dec 30, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 5/245 20130101;
B32B 9/046 20130101; B32B 2260/04 20130101; F02C 7/18 20130101;
Y10T 156/10 20150115; B32B 18/00 20130101; B32B 2307/724 20130101;
B32B 2603/00 20130101; C04B 37/005 20130101; Y10T 428/24997
20150401; B32B 2250/40 20130101; F05D 2300/6033 20130101; B32B 5/18
20130101; C04B 2237/04 20130101; B32B 9/007 20130101; C04B 2237/38
20130101; B32B 2266/04 20130101; B32B 2266/06 20130101; B32B 9/005
20130101; B32B 5/26 20130101; F05D 2300/612 20130101; C04B 2237/62
20130101; B32B 5/22 20130101; B32B 2250/20 20130101; B32B 5/24
20130101; C04B 2237/32 20130101; B32B 2307/306 20130101; Y10T
442/335 20150401; B32B 2250/03 20130101; B32B 2250/42 20130101;
B32B 2307/726 20130101; Y10T 428/24331 20150115; F01D 5/18
20130101 |
International
Class: |
F02C 7/18 20060101
F02C007/18; C04B 37/00 20060101 C04B037/00; B32B 9/04 20060101
B32B009/04; B32B 18/00 20060101 B32B018/00; B32B 5/18 20060101
B32B005/18; B32B 9/00 20060101 B32B009/00 |
Claims
1. A method, comprising: forming a first ceramic matrix composite
(CMC) sheet, and providing a plurality of flow paths therethrough;
rigidizing the first CMC sheet into a component shape; bonding a
shaped, open-cell CMC foam layer to the first CMC sheet; forming a
second CMC sheet; bonding the second CMC sheet to the foam layer
thereby forming a component structure; and curing the component
structure.
2. The method of claim 1, further comprising providing a plurality
of flow paths through the second CMC sheet before the bonding the
second CMC sheet.
3. The method of claim 2, wherein providing the plurality of flow
paths through the second CMC sheet comprises perforating the second
CMC sheet.
4. The method of claim 3, further comprising applying a thermal and
environmental barrier coating to the second CMC sheet before the
perforating.
5. The method of claim 1, further comprising providing the
plurality of flow paths through the first CMC sheet and the second
CMC sheet by perforating the CMC sheets.
6. The method of claim 5, further comprising staggering the
perforations of the first CMC sheet and the second CMC sheet.
7. The method of claim 5, further comprising aligning the
perforations of the first CMC sheet and the second CMC sheet.
8. The method of claim 1, further comprising: determining a
component strength requirement; in response to the component
strength requirement, determining at least one design parameter
selected from the parameters comprising: a number of layers each
layer comprising a CMC foam layer interposed between two CMC
sheets, a thickness of each of the CMC sheets, a density of the CMC
foam layer, and a geometric shape of the component structure; and
conforming the component structure to the at least one design
parameter.
9. The method of claim 1, further comprising: determining a
component cooling capability requirement; in response to the
component cooling capability requirement, determining at least one
design parameter selected from the parameters comprising: a sizing
of the flow paths, a shape factor of the flow paths, an alignment
value of the flow paths, a thermal and environmental barrier
coating design, and a density of the CMC foam layer; and conforming
the component structure to the at least one design parameter.
10. A method, comprising: providing a multi-layer ceramic matrix
composite (CMC) component comprising two opposing CMC sheets and a
CMC open-cell foam layer therebetween; exposing one of the CMC
sheets directly to high-temperature turbine engine gases; and
flowing a coolant fluid through the CMC open-cell foam layer and
through a plurality of flow passages defined by at least one of the
CMC sheets.
11. The method of claim 10, wherein the exposing comprises flowing
turbine engine combustion gases in contact with the one of the CMC
sheets.
12. The method of claim 11, further comprising rotating the
multi-layer CMC component during the exposing.
13. The method of claim 10, wherein the flowing comprises providing
a first heat transfer value from the multi-layer CMC component to
the coolant fluid that is lower than a second heat transfer value,
the second heat transfer value comprising a required heat transfer
for a metal component.
14. A method, comprising: forming a first ceramic matrix composite
(CMC) sheet, and providing a plurality of flow paths therethrough;
rigidizing the first CMC sheet into a component shape; bonding a
shaped, open-cell CMC foam layer to the first CMC sheet; forming a
second CMC sheet; providing a plurality of flow passages through
the second CMC sheet; bonding the second CMC sheet to the foam
layer after the providing a plurality of flow passages step,
thereby forming a component structure; and curing the component
structure.
15. The method of claim 14, further comprising applying a thermal
and environmental barrier coating to the second CMC sheet before
the providing a plurality of flow passages step.
16. The method of claim 14, further comprising providing the
plurality of flow passages through the first CMC sheet prior the
bonding a shaped, open-cell CMC foam layer to the first CMC sheet
step.
17. The method of claim 16, wherein the flow passages of the first
CMC sheet are staggered relative to the flow passages of the second
CMC sheet.
18. The method of claim 16, wherein the flow passages of the first
CMC sheet are aligned with the flow passages of the second CMC
sheet.
19. The method of claim 14, further comprising rigidizing the
second CMC sheet prior to the providing a plurality of flow
passages through the second CMC sheet step.
Description
RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No.
13/337,106, filed Dec. 24, 2011, which claims the benefit of United
States Provisional Patent Application No. 61/428,701, filed Dec.
30, 2010, which is incorporated herein by reference.
BACKGROUND
[0002] The technical field generally relates to high-temperature,
light-weight materials. Ceramic matrix composite materials in the
presently known art have limitations in the structural capabilities
and the cooling methods available. Presently available ceramic
components are cooled by direct flow or impingement cooling.
Further, presently available metal materials require high cooling
loads to achieve sufficient cooling in high-temperature
applications, requiring low temperature cooling fluids and/or high
cooling fluid flow rates. Therefore, further technological
developments are desirable in this area.
SUMMARY
[0003] One embodiment is a unique article of manufacture including
a ceramic matrix composite, a ceramic matrix composite foam layer
and another ceramic matrix composite bonded thereto. Other
embodiments include unique methods, systems, and apparatus to
related to the article of manufacture and method of manufacture.
Further embodiments, forms, objects, features, advantages, aspects,
and benefits shall become apparent from the following description
and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1a is a schematic diagram of a multi-layer porous
composite structure.
[0005] FIG. 1b is an exploded view of a multi-layer porous
composite structure.
[0006] FIG. 2 is a schematic diagram of a multi-layer porous
composite structure having a woven layer.
[0007] FIG. 3 is a schematic diagram of a component formed from a
multi-layer porous composite structure.
[0008] FIG. 4 is schematic diagram of another multi-layer porous
composite structure.
DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0009] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended, any alterations and further modifications in the
illustrated embodiments, and any further applications of the
principles of the invention as illustrated therein as would
normally occur to one skilled in the art to which the invention
relates are contemplated herein.
[0010] Referencing FIG. 1, an article of manufacture 100 is
illustrated having a first ceramic matrix composite (CMC) sheet
102. In certain embodiments, the CMC sheet may be woven (e.g.
reference FIG. 2), braided, or formed by standard processing. The
article 100 includes flow passages 104 through the first CMC sheet
102, and a CMC foam layer 106 bonded to the first CMC sheet 102.
The CMC foam layer 106 is an open-cell foam, allowing fluid flow
through the bulk of the CMC foam layer 106. The article of
manufacture 100 further includes a second CMC sheet 108 bonded to
the CMC foam layer 106. The flow permeability through the foam and
the structural contribution of the foam layer to the article 100
are selectable according to the foam cell sizing and density.
[0011] An exemplary embodiment includes forming and rigidizing the
first CMC sheet 102 before application and bonding of the CMC foam
sheet 106, then applying the second CMC sheet 108. In certain
embodiments, article 100 further includes flow passages 110
(reference FIG. 1b) through the second CMC sheet 108. The article
100 may be processed to completion (e.g. rigidizing and de-greening
the article) after the application of the second CMC sheet 108, or
the second CMC sheet 108 may be rigidized before the application of
further layers. An exemplary article of manufacture 400 (reference
FIG. 4) includes additional CMC foam layer(s) 402, each additional
CMC foam layer 402 bonded to and alternated with a CMC sheet (108,
404). Each of the CMC sheets (102, 108, 404) may be perforated
(drilled, punched, etc.) after rigidizing. In certain embodiments,
one or more of the sheets 102, 108, 404 do not include flow
passages therethrough. In certain embodiments, the flow passages
through the sheets 102, 108, 404 are inherent to the sheet
construction--for example where the sheets 102, 108, 404 have a
braided or woven construction having gas permeable gaps.
[0012] Returning to FIG. 1a, in certain embodiments, the
perforations 104, 110 may be staggered or aligned to facilitate the
desired flow permeability through the article 100. For example, the
perforations 104, 110 may be in any degree of alignment between
direct alignment and maximum possible average offset. The flow
permeability through the article 100 is further selectable with the
sizing and count of the perforations 104, 110. Thus, a configurable
flow permeability is provided through the article 100, or from the
interior of the article 100 through one or both of the sheets 102,
108.
[0013] The article of manufacture 100 may be a component including
a cooled gas turbine engine combustion chamber liner, a non-cooled
gas turbine engine combustion chamber liner, a cooled gas turbine
engine exhaust liner, a non-cooled gas turbine engine exhaust
liner, a cooled rotating blade for a gas turbine, a non-cooled
rotating blade for a gas turbine, a cooled vane for a gas turbine,
and/or a non-cooled vane for a gas turbine. In certain embodiments,
the second CMC sheet 108 includes a thermal and environmental
barrier coating. Any of the CMC sheets 102, 108, 404, and
especially any CMC sheets exposed to a heated and/or corrosive
environment, may include a thermal and/or environmental barrier
coating.
[0014] Referencing FIG. 3, schematic diagram of a component 300
formed from a multi-layer porous composite structure is
illustrated. The exemplary component 300 is a compressor blade, a
turbine blade, or a stator vane. The component includes a first CMC
sheet 102, a second CMC sheet 108, and an open-cell CMC foam layer
106. The component 300 is mechanically coupled to a base 308 (e.g.
a compressor hub), the base 308 including a coolant passage 306
that flows coolant into the component 300. The exemplary component
300 includes flow passages 104 in only one of the CMC sheets, where
the coolant flow 302 enters the gases passing by the component 300.
A component 300 may include flow passages 104 in either of the
sheets 102, 108, and/or both of the sheets 102, 108. In certain
embodiments, the component 300 is a ceramic composite component
that withstands high temperatures and has some internal cooling
capability from the coolant flow 302 therethrough. The heat
transfer value from the component 300 to the coolant flow 302 may
be provided at a lower value than a heat transfer value that would
be required for a metallic component to avoid failure. Accordingly,
adjustments to the size of the coolant passage 306, the coolant
flow rate, the coolant temperature, and/or other modification of
the coolant flow environment through the component 300 may be made
to lower costs and/or improve reliability of the component 300
relative to a metallic component performing a similar structural
function. Exemplary, non-limiting adjustments include: providing a
smaller coolant passage 306, providing a lower coolant flow rate,
and providing a higher coolant temperature.
[0015] The procedural descriptions which follow provide an
illustrative embodiment of performing procedures for providing a
multi-layer ceramic composite porous structure. Operations
illustrated are understood to be exemplary only, and operations may
be combined or divided, and added or removed, as well as re-ordered
in whole or part, unless stated explicitly to the contrary herein.
Certain operations illustrated may be implemented by a computer
executing a computer program product on a computer readable medium,
where the computer program product comprises instructions causing
the computer to execute one or more of the operations, or to issue
commands to other devices to execute one or more of the
operations.
[0016] An exemplary procedure includes an operation to provide a
multi-layer ceramic matrix composite (CMC) component having two
opposing CMC sheets and a CMC open-cell foam layer therebetween.
The procedure further includes an operation to expose one of the
CMC sheets directly to high-temperature turbine engine gases. The
exemplary procedure further includes an operation to flow a coolant
fluid through the CMC open-cell foam layer and through at least one
of the CMC sheets. In certain embodiments, the procedure further
includes exposing the CMC sheet directly to high-temperature
turbine engine gases by flowing turbine engine combustion gases in
contact with the CMC sheet. Exemplary embodiments include rotating
the multi-layer CMC component during the exposing, for example
where the multi-layer CMC component is a rotating blade including a
combustion gas turbine blade mechanically coupled to an upstream
compressor blade.
[0017] In certain embodiments, the procedure includes providing a
first heat transfer value from the multi-layer CMC component to the
coolant fluid that is lower than a second heat transfer value. The
second heat transfer value is a required heat transfer for a metal
component. The heat transfer values comprise an amount of heat
removed from the component per unit of time relative to a given
exhaust temperature and flow rate. In certain embodiments, the heat
transfer value is relatable to an operating temperature of the
component, where the second heat transfer value is lowered thereby
providing a higher operating temperature for the multi-layer CMC
component than would be required for a metal component performing
an identical structural task. The metal component may be a
superalloy, steel, titanium, aluminum, or other metal component
that could be configured to provide a mechanically similar function
in a similar application.
[0018] Another exemplary procedure includes an operation to form a
first ceramic matrix composite (CMC) sheet, and an operation to
provide a number of flow paths therethrough (e.g. by perforating
the first CMC sheet or by forming the CMC sheet with inherent gas
permeable passageways). The procedure further includes an operation
to rigidize the first CMC sheet into a component shape. In certain
embodiments, the rigidizing is performed before the providing the
flow paths.
[0019] The procedure further includes an operation to bond a
shaped, open-cell CMC foam layer to the first CMC sheet, where the
shaped, open-cell CMC foam layer has a shape corresponding to the
component shape. For example, the component may be an airfoil vane
utilized in a turbine engine, and the first CMC sheet and CMC foam
layer form one face and an interior of the airfoil vane. The
exemplary procedure further includes an operation to form a second
CMC sheet, and an operation to bond the second CMC sheet to the
foam layer thereby forming a component structure. The procedure
further includes an operation to cure the component structure. In
certain embodiments, the procedure includes an operation to provide
a number of flow paths through the second CMC sheet before the
operation to bond the second CMC sheet. In certain embodiments, the
procedure includes an operation to apply a thermal and
environmental barrier coating to the second CMC sheet.
[0020] In certain embodiments, the exemplary procedure further
includes, before the curing the component structure, an operation
to rigidize the second CMC sheet, to bond a second shaped,
open-cell CMC foam layer to the second CMC sheet, to form a third
CMC sheet, and to bond the third CMC sheet to the second foam layer
thereby enlarging the component structure. Certain embodiments of
the procedure include operations to add open-cell CMC foam layers
and additional CMC sheet layers to build the component to a
specified configuration.
[0021] An exemplary embodiment of the procedure includes an
operation to determine a component strength requirement, and in
response to the component strength requirement, to determine at
least one design parameter. The design parameter includes a number
of layers each layer comprising a CMC foam layer interposed between
two CMC sheets, a thickness of each of the CMC sheets, a density of
the CMC foam layer, and/or a geometric shape of the component
structure. The procedure further includes conforming the component
structure to the design parameter(s).
[0022] Another exemplary embodiment of the procedure includes an
operation to determine a component cooling capability requirement,
and in response to the component cooling capability requirement, to
determine at least one design parameter. The design parameter
includes a sizing of the flow paths, a shape factor of the flow
paths, an alignment value of the flow paths, a thermal and
environmental barrier coating design, and/or a density of the CMC
foam layer.
[0023] An exemplary shape factor includes a contribution of the
pressure drop of flow through the component that results from the
geometrical aspects of the component, including the component
thickness, overall shape, the number of flow paths provided in the
CMC sheets and CMC foam layer, and other geometrical aspects
understood in the art. An exemplary alignment value of the flow
paths includes a degree to which an average flow path provided in a
first CMC sheet aligns or is displaced from an average flow path
provided in a second CMC sheet. The procedure further includes an
operation to conform the component structure to the design
parameter.
[0024] As is evident from the figures and text presented above, a
variety of embodiments according to the present invention are
contemplated.
[0025] An exemplary embodiment is an article of manufacture,
including a first ceramic matrix composite (CMC) sheet having flow
passages therethrough and a CMC foam layer bonded to the first CMC
sheet, where the CMC foam layer is an open-cell foam. The article
of manufacture further includes a second CMC sheet bonded to the
CMC foam layer. Certain embodiments of the article of manufacture
include a number of flow passages through the second CMC sheet, and
the perforations may be staggered or aligned to facilitate the
desired flow permeability through the article of manufacture, or
through the relevant portion of the article of manufacture. The
flow passages may be perforations in the first and/or second CMC
sheets. In certain embodiments, the flow passages are gas permeable
gaps in the CMC sheets formed by woven and/or braided CMC sheets.
The article of manufacture may include additional CMC foam layers,
with each CMC foam layer bonded with and alternated with a CMC
sheet.
[0026] In certain embodiments, the article of manufacture further
includes additional CMC foam layers, where each of the additional
CMC foam layers is bonded to and alternated with an additional CMC
sheet. The article of manufacture may be a component including a
cooled gas turbine engine combustion chamber liner, a non-cooled
gas turbine engine combustion chamber liner, a cooled gas turbine
engine exhaust liner, a non-cooled gas turbine engine exhaust
liner, a cooled rotating blade for a gas turbine, a non-cooled
rotating blade for a gas turbine, a cooled vane for a gas turbine,
and a non-cooled vane for a gas turbine. In certain embodiments,
the second CMC sheet includes a thermal and environmental barrier
coating. Any of the CMC sheets, and especially any exposed CMC
sheets to a heated and/or corrosive environment, may include a
thermal and/or environmental barrier coating.
[0027] Another exemplary embodiment is a method, including
providing a multi-layer ceramic matrix composite (CMC) component
having two opposing CMC sheets and a CMC open-cell foam layer
therebetween. The method includes exposing one of the CMC sheets
directly to high-temperature turbine engine gases, and flowing a
coolant fluid through the CMC open-cell foam layer and also through
at least one of the CMC sheets. The exemplary method further
includes exposing the CMC sheet directly to high-temperature
turbine engine gases by flowing turbine engine combustion gases in
contact with the CMC sheet. The method may further include rotating
the multi-layer CMC component during the exposing, for example
where the multi-layer CMC component is a rotating blade including a
combustion gas turbine blade mechanically coupled to an upstream
compressor blade. In certain embodiments, the method further
includes providing a first heat transfer value from the multi-layer
CMC component to the coolant fluid that is lower than a second heat
transfer value, where the second heat transfer value is a required
heat transfer for a metal component. The metal component may be a
superalloy, steel, titanium, aluminum, or other metal component
that could be configured to provide a mechanically similar function
in a similar application.
[0028] Yet another exemplary embodiment is a method including
forming a first ceramic matrix composite (CMC) sheet, and providing
a number of flow paths therethrough. The method further includes
rigidizing the first CMC sheet into a component shape and bonding a
shaped, open-cell CMC foam layer to the first CMC sheet, where the
shaped, open-cell CMC foam layer has a shape corresponding to the
component shape. The method further includes forming a second CMC
sheet, and bonding the second CMC sheet to the foam layer thereby
forming a component structure. The method further includes curing
the component structure. In certain embodiments, the method
includes providing a number of flow paths through the second CMC
sheet before the bonding the second CMC sheet. The flow paths may
be provided by perforating the first CMC sheet and/or the second
CMC sheet. In certain embodiments, the method includes applying a
thermal and environmental barrier coating to the second CMC sheet
before the perforating. The perforations for the first CMC sheet
and the second CMC sheet may be staggered.
[0029] In certain embodiments, the method further includes, before
the curing the component structure: rigidizing the second CMC
sheet, bonding a second shaped, open-cell CMC foam layer to the
second CMC sheet, forming a third CMC sheet, and bonding the third
CMC sheet to the second foam layer thereby enlarging the component
structure. Certain embodiments of the method include determining a
component strength requirement, and in response to the component
strength requirement, determining at least one design parameter
including: a number of layers each layer comprising a CMC foam
layer interposed between two CMC sheets, a thickness of each of the
CMC sheets, a density of the CMC foam layer, and/or a geometric
shape of the component structure. The method further includes
conforming the component structure to the design parameter(s). The
method further includes, in certain embodiments, determining a
component cooling capability requirement, and in response to the
component cooling capability requirement, determining at least one
design parameter including: a sizing of the flow paths, a shape
factor of the flow paths, an alignment value of the flow paths, a
thermal and environmental barrier coating design, and/or a density
of the CMC foam layer. The method further includes conforming the
component structure to the design parameter(s).
[0030] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only certain exemplary embodiments have been
shown and described and that all changes and modifications that
come within the spirit of the inventions are desired to be
protected. In reading the claims, it is intended that when words
such as "a," "an," at least one," or at least one portion" are used
there is no intention to limit the claim to only one item unless
specifically stated to the contrary in the claim. When the language
at least a portion" and/or "a portion" is used the item can include
a portion and/or the entire item unless specifically stated to the
contrary.
* * * * *