General Electric Company

Daniel Gene Dunn

Jared Hogg Weaver

Douglas Glenn Decesare

Gregory Scot Corman

James Scott Vartuli

Matthew Harper Hockemeyer

James Anthony Ruud

Jason David Shapiro

Suresh Subramanian

Douglas Melton Carper

Michael Ray Tuertscher

Henry Charles McGuigan

Juan Borja

Pierre-Andre Bui

Jerome Geoffrey Magnant

Daniel George Norton

Michael Alan Vallance

Jason Robert Parolini

Thomas Earl Dyson

David Bruce Hall

Shatil Sinha

James Murray

Brian Gregg Feie

Sara Saxton Underwood

Anant Achyut Setlur

Herbert Chidsey Roberts

Steven Robert Hayashi

Mark Eugene Noe

Glenn Curtis Taxacher

James Dale Steibel

Changjie Sun

Toby George Darkins, Jr

Dennis Joseph Coyle

Brandon ALlanson Reynolds

Mark Stewart Schroder

Reza Sarrafi-Nour

Anteneh Kebbede

Timothy P Coons

Christopher Jon Potokar

Nolan Leander Cousineau

Christopher Grace

Krishnan Balaji Thattai Parthasarathy

Nathan Carl Sizemore

Kurtis C Montgomery

K M K Genghis Khan

Brandon ALIanson Reynolds

Steven James Murphy

Kmk Genghis Khan

Mackenzie Christopher Hock

Sara Underwood

MIchael Schuster

Henry Charles Mcguigan

Brandon Allanson Reynolds

Gregory Scott Corman

A composite component for a gas turbine engine is provided, along with its methods of formation. The composite component includes: an additively printed inner portion defining at least one flowpath feature, and a ceramic matrix composite (CMC) outer portion formed on the additively printed inner portion such that the CMC outer portion substantially surrounds the additively printed inner portion. The additively printed inner portion includes SiC; and the CMC outer portion includes a fiber reinforced ceramic matrix (e.g., including SiC) and defines at least one cooling cavity fluidly coupled to the at least one flowpath feature of the additively printed inner portion.

Composite component having an additively printed inner portion

A ceramic matrix composite (CMC) component and method of forming the CMC component with multiple layers of impregnated matrix fibers, at least one of the multiple layers including at least one CMC prepreg formed from a plurality of twisted tows, twisted through at least one turn/meter.

Ceramic matrix composite component and method of forming

A method for modifying a composite component may include positioning a barrier segment between an infiltrated segment of the composite component and a green segment to form an assembly; and initiating an infiltration process. The barrier segment may have a barrier segment permeability that is lower than a permeability of the infiltrated segment, a permeability of the green segment, or both. A composite component may include an infiltrated segment infiltrated with a molten material during a prior infiltration process; a green segment that is uninfiltrated; and a barrier segment having a microstructure different from the infiltrated segment, the green segment, or both. The microstructure of the barrier segment may be configured to slow a flow of material between the infiltrated segment and the green segment during a subsequent infiltration process.

Composite components and methods for preventing flow from infiltrated component during re-infiltration

Composite components and methods for adding a composite material to a composite component are provided. For example, a method comprises positioning a composite material segment against the composite component to form a component layup; applying an insulating material around at least a portion of the component layup to form an insulated layup; and densifying the insulated layup, where the composite component was previously densified before positioning the composite material segment against the composite component. In some embodiments, the composite material is ceramic matrix composite (CMC) and the composite material segment is a plurality of CMC plies. The composite component may be a CMC gas turbine engine component that comprises an original CMC component and a new CMC material segment joined to the original CMC component through the transfer of silicon between the original CMC component and the new CMC material segment during melt infiltration.

Composite component modifications

Provided is a method including obtaining ceramic matrix composite (CMC) with a first matrix portion including a silicon carbide and silicon phase dispersed therewithin, disposing a coating thereupon to form a sealed part, and forming thereupon another segment comprising a CMC, which may be another matrix portion including a silicon carbide and a silicon phase dispersed within therewithin. Also provided is a gas turbine component with a CMC segment including a matrix portion including a silicon carbide and a silicon phase dispersed therewithin, a sealing layer including silicon carbide enclosing the first segment, and a second segment on the sealing layer, wherein the second segment includes a melt-infiltrated CMC having a matrix portion including a silicon carbide and a silicon phase dispersed therewithin.

Seal coats to prevent silicon loss during re-melt infiltration of Si containing composites

Ceramic matrix composite articles include, for example a first plurality of plies of ceramic fibers in a ceramic matrix defining a first extent, and a local at least one second ply in said ceramic matrix defining a second extent on and/or in said first plurality of plies with the second extent being less than said first extent. The first plurality of plies has a first property, the at least one second ply has at least one second property, and said first property being different from said at least one second property. The different properties may include one or more different mechanical (stress/strain) properties, one or more different thermal conductivity properties, one or more different electrical conductivity properties, one or more different other properties, and combinations thereof.

Ceramic matrix composite articles having different localized properties and methods for forming same

Methods for forming a unitary ceramic component are provided. The method may include: positioning a braze reactant layer in a contact area between a first densified ceramic component and a second densified ceramic component; positioning a pack material around at least a portion of the first densified ceramic component or the second densified ceramic component; positioning at least one infiltrate source in fluid communication with the braze reactant layer; and thereafter, heating the at least one infiltrate source, the pack material, the first densified ceramic component, and the second densified ceramic component to a braze temperature that is at or above a melting point of at least one phase of the infiltrate composition such that at least one phase of infiltrate composition melts and flows into the braze reactant layer and reacts with a ceramic precursor compound therein to form a ceramic material.

Methods for joining ceramic components to form unitary ceramic components

A ceramic matrix composite (CMC) component including a first subcomponent and a second subcomponent. The first component formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix and the second CMC subcomponent formed of one of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix or a monolithic ceramic material. The subcomponents further including an interlocking mechanical joint joining the first subcomponent and the second subcomponent to form the composite material component. The interlocking mechanical joint including at least one groove defined in one of the first subcomponent or the second subcomponent and into which a portion of the other of the first subcomponent or the second subcomponent is disposed. A shroud segment is provided formed of the joined first and second subcomponents. Methods are also provided for joining the first and second subcomponents using an interlocking mechanical joint.

CMC component and fabrication using mechanical joints

A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.

CMC shroud segment with interlocking mechanical joints and fabrication

A nozzle including a vane and a band, each having defined therein interlocking features. The vane and the band are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The vane and the band include one or more interlocking features. The nozzle further including an interlocking mechanical joint joining the vane and the band to one another. Methods are also provided for joining the vane and the band at the interlocking features to form an interlocking mechanical joint.

CMC nozzle with interlocking mechanical joint and fabrication

A ceramic matrix composite (CMC) component including a plurality of layers of a CMC and a directionally controllable CMC insert. The directionally controllable CMC insert is disposed in the plurality of layers of a ceramic matrix composite. The directionally controllable CMC insert includes an optimized architecture to strengthen a high stress region of the CMC component. The directionally controllable CMC insert is geometrically configured and disposed within the plurality of layers of the CMC to redirect a crack in the CMC component toward a region of low crack growth driving force. A turbomachine and method of forming a turbomachine member including a plurality of layers of a CMC and having the directionally controllable CMC insert disposed in a shaped void are additionally disclosed.

CMC component including directionally controllable CMC insert and method of fabrication

A method of producing a ceramic matrix composite component. The method includes positioning a first plurality of ceramic matrix composite plies on top of one another, disposing a filler pack on the first plurality of ceramic matrix composite plies, and positioning a second plurality of ceramic matrix composite plies on top of the filler pack. One of the first plurality of ceramic composite plies or the second plurality of ceramic composite plies includes a bend angle, to define an interstice between the plurality of ceramic matrix composite plies with the filler pack disposed in the interstice. The filler pack includes one or more sacrificial fibers disposed therein, that subsequent to removal provide a functional feature, such as a cooling manifold in the filler pack. The method further includes forming one or more channels coupled to the one or more functional features for the flow of a cooling fluid therethrough. A ceramic matrix composite is also disclosed.

Ceramic matrix composite component and method of producing a ceramic matrix composite component

A ceramic matrix composite (CMC) component and method of fabrication including one or more elongate functional features formed in multiple fiber plies of the CMC component. The CMC component includes a plurality of longitudinally extending ceramic matrix composite plies in a stacked configuration. Each of the one or more elongate functional features includes an inlet and an outlet to provide a flow of fluid from a fluid source to an exterior of the ceramic matrix composite component. The one or more elongate functional features are configured in multiple plies of the plurality of longitudinally extending ceramic matrix composite plies to form a plurality of cooling channels in multiple plies of the ceramic matrix composite component.

Ceramic matrix composite component including cooling channels in multiple plies and method of producing

Methods for preparing ceramic matrix composites using melt infiltration and chemical vapor infiltration are provided as well as the resulting ceramic matrix composites. The methods and products include the incorporation of sacrificial fibers to provide improved infiltration of the fluid infiltrant. The sacrificial fibers are removed, such as decomposed during pyrolysis, resulting in the formation of regular and elongate channels throughout the ceramic matrix composite. Infiltration of the fluid infiltrant can then take place using the elongate channels resulting in improved density and an improved ceramic matrix composite product.

Methods of forming ceramic matrix composites using sacrificial fibers and related products

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Guilderland, NY, United States of America

Daniel Gene Dunn