Siemens Energy, Inc.

Coi Ceramics, Inc.

Alliant Techsystems Inc.

Andrew Szweda

Jay Alan Morrison

Timothy E Easler

Eric Stein

Jay Edgar Lane

Thomas Barrett Jackson

Steven C Butner

A method of forming a ceramic matrix composite structure. The method comprises forming at least one prepregged composite material comprising a ceramic fiber preform and a pre-ceramic matrix slurry. The at least one prepregged composite material is placed over at least one surface of a tool using an advanced fiber placement apparatus to form an at least partially uncured composite material structure. The at least partially uncured composite material structure is exposed at least to elevated temperatures to convert the at least partially uncured composite material structure into a ceramic matrix composite structure. A system for forming a ceramic matrix composite structure, an advanced fiber placement apparatus, and a ceramic matrix composite structure are also described.

Methods of forming ceramic matrix composite structures

A precursor formulation of a silicon carbide material that includes a ceramic material and a boron-11 compound. The ceramic material may include silicon and carbon and, optionally, oxygen, nitrogen, titanium, zirconium, aluminum, or mixtures thereof. The boron-11 compound may be a boron-11 isotope of boron oxide, boron hydride, boron hydroxide, boron carbide, boron nitride, boron trichloride, boron trifluoride, boron metal, or mixtures thereof. A material for use in a nuclear reactor component is also disclosed, as are such components, as well as a method of producing the material.

Method of forming a silicon carbide material, and structures including the material

Aspects of the invention relate to a construction system and method for components in high temperature environments, such as the hot gas path components of a turbine engine. Such a component can include a skeleton and a coating. The skeleton can be formed by a plurality of interconnected frame members, which can give the component its general shape. The frame members can be made of ceramic matrix composite. A coating can be provided around at least a portion of the skeleton. Preferably, the coating is a refractory material, such as refractory ceramic. Examples of turbine engine components that can be constructed according to aspects of the invention are airfoils with or without platforms, blade rings, combustor tiles and heat shields. A component according to aspects of the invention can be made using low cost fabrication and construction methods.

Refractory component with ceramic matrix composite skeleton

A ceramic matrix composite (CMC) material () with increased interlaminar strength is obtained without a corresponding debit in other mechanical properties. This is achieved by infusing a diffusion barrier layer () into an existing porous matrix CMC to coat the exposed first matrix phase () and fibers (), and then densifying the matrix with repeated infiltration cycles of a second matrix phase (). The diffusion barrier prevents undesirable sintering between the matrix phases and between the second matrix phase and the fibers during subsequent final firing and use of the resulting component () in a high temperature environment.

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San Diego, CA, United States of America

Andrew Szweda