Rockwell International Corporation

The Boeing Company

Teledyne Scientific and Imaging, LLC

University of California

Boeing North American, Inc.

Innovative Technology Licensing LLC

Rockwell Int'l Corp.

David Bruce Marshall

Peter E Morgan

Janet B Davis

Olivier H Sudre

Brian Nelson Cox

Sergio Luis Dos Santos E Lucato

Joseph J Ratto

Roger E De Wames

Ira B Goldberg

Frederick F Lange

William F Hall

Min Zhou Berbon

Peter E D Morgan

John Richard Porter

Julia Jeannine Mack

Kris Shigeko Oka

Daniel Edward Driemeyer

Peter Ernest David Morgan

Brock S McCabe

Craig A Folsom

Janet D Davis

An integral textile structure for 3-D CMC turbine airfoils includes top and bottom walls made from an angle-interlock weave, each of the walls comprising warp and weft fiber tows. The top and bottom walls are merged on a first side parallel to the warp fiber tows into a single wall along a portion of their widths, with the weft fiber tows making up the single wall interlocked through the wall's thickness such that delamination of the wall is inhibited. The single wall suitably forms the trailing edge of an airfoil; the top and bottom walls are preferably joined along a second side opposite the first side and parallel to the radial fiber tows by a continuously curved section in which the weave structure remains continuous with the weave structure in the top and bottom walls, the continuously curved section being the leading edge of the airfoil.

Integral textile structure for 3-D CMC turbine airfoils

In one embodiment, a morphable composite three-dimensional structure is disclosed. The morphable composite three-dimensional structure comprises a flexible fiber-reinforced ceramic composite comprising a fiber preform and a ceramic matrix material infused therein. The flexible fiber-reinforced ceramic composite defines a flowpath having a three-dimensional cross-section. The cross-section of the flowpath is variable along the length of the flowpath. A plurality of anchors are integrally formed in the fiber preform. The plurality of anchors extend through a thickness of the ceramic matrix. The plurality of anchors are configured to couple to at least one actuator. The at least one actuator is actuatable to vary the three-dimensional cross-section of the flowpath.

Morphing ceramic composite components for hypersonic wind tunnel

Aqueous precursor solutions are described that comprise at least one monazite-based material precursor, at least one xenotime-based material precursor or a combination thereof; and a plurality of fine suspended particles of an oxide material. Contemplated oxide composites, as described herein, comprise a plurality of fibers surrounded by at least one monazite or xenotime-based material, wherein the oxide composite has nearly a fully dense matrix. Contemplated embodiments disclosed herein provides a method for producing an oxide composite with nearly fully dense matrix and with all fibers surrounded by a monazite- or xenotime-based material that prevents embrittlement at temperatures at least as high as 1200&#xb0; C. Oxide composites are described that contain a plurality of fibers, a matrix containing at least one or more oxide materials, and at least one monazite-based material, xenotime-based material or combination thereof, wherein the monazite-based or xenotime-based material is formed from the aqueous precursor solutions disclosed herein. Contemplated methods of production include: a) providing a composite comprising oxide-reinforcing fibers and a porous matrix of oxide materials, and b) infiltrating the porosity in the matrix with a solution that contains precursors for at least one monazite-based material, at least one xenotime-based material or a combination thereof; and c) heat treating the composite to convert the precursors to monazite, xenotime, or combinations thereof.

Use of monazite or xenotime solution precursors to increase the density and shear strength of oxide composites

An apparatus and method for an improved morphing flow path. A flexible structure has a plurality of sections which include a first section and a second section. An actuator system is connected to the flexible structure and includes a number of actuators. The actuator system is capable of changing a configuration of the flexible structure. A controller is connected to the actuator system. The controller is capable of changing a position of a number of actuators within the actuator system.

Tailorable stiffness shape morphing flow-path

A protective hybrid composite for a rotor blade is based on the use of tape cast ceramic layers densified by pre-ceramic polymer infiltration methods and laminated together with polymer matrix composite prepregs, with or without an embedded metallic mesh, to form a conforming helicopter blade cladding that is laminated to the blade surface for added erosion protection. The hybrid composite is fabricated to net shape and laminated to the blade using either an adhesive or a polymer composite prepreg inner layer. Installation is accomplished by a standard composite fabrication method of vacuum bagging the blade while the system is laminated to its surface. Repair methods based on removal of ceramic tiles is facilitated by incorporation of a metallic mesh element laminated beneath the ceramic tiles that can be used to heat the tile and decrease its adhesion strength.

Hybrid composite for erosion resistant helicopter blades

Devices, systems and methods for fabricating improved ceramic composite turbine shrouds with abradable seals are disclosed. A high temperature seal with an abradable coating is provided. The seal comprises a three-dimensional, high-density woven composite base structure recessed below the abradable coating, with loops incorporated in and protruding from the base structure. The abradable coating is integrally attached to the base structure via the loops. Additionally, a graded density seal is provided with a three-dimensional, low-density woven composite structure. The low-density structure is abradable. A three-dimensional, high-density woven composite base structure is recessed below the low-density structure, with the low-density structure integrally attached to the base structure via weaving.

Integral abradable seals

An exemplary morphable ceramic composite structure includes a flexible ceramic composite skin and a truss structure attached to the skin. The truss structure can morph shape of the skin from a first shape to a second shape that is different than the first shape. The flexible ceramic composite skin may include a single-layer of three-dimensional woven fabric fibers and a ceramic matrix composite. The truss structure may include at least one actuatable element or an actuator may move a portion of the truss structure from a first position to a second position. A cooling component may be disposed in thermal communication with the skin. The cooling component may include thermal insulation or a cooling system that circulates cooling fluid in thermal communication with the skin. The morphable ceramic composite structure may be incorporated into any of an air inlet, combustor, exhaust nozzle, or control surfaces of a hypersonic aircraft.

Morphable ceramic composite skins and structures for hypersonic flight

A self-transpiring hot skin for a hypersonic or reusable space vehicle that can provide protection to the vehicle during short periods of abnormally high heat flux (either planned in the flight profile or an off-nominal event). The hot skin includes a ceramic composite structure having an internal cavity that is coupled either to the insulating layer or directly to the support structure of the hypersonic vehicle. The internal cavity includes a material system that vaporizes, sublimes or decomposes into a gas when the temperature exceeds the upper temperature capability of the composite material. The gas transpires through the outer layer of the composite material to provide cooling to the outer layer below the upper temperature capability. Cooling may occur both by conduction of heat from the composite material to the transpiring gas and by the interaction of the transpiring gas with the boundary layer of hypersonic flow over the outer surface, leading to a reduction of the heat flux entering the surface.

Materials for self-transpiring hot skins for hypersonic vehicles or reusable space vehicles

Monazites and xenotimes are rare-earth phosphates showing a combination of properties expected to be suitable for thermal barrier coatings. For example, lanthanum phosphate (La-monazite) can be used to form thermal barrier coatings to protect superalloy and ceramic parts exposed to high temperature and damage by sulfur, vanadium, phosphorus and other contaminants. The monazite or xenotime coatings can be applied using any of the common application methods including EB-PVD, laser ablation and plasma spraying. The stoichiometry of the coatings can be modulated according to the stoichiometry of specially prepared starting target (source) material. The most effective coatings appear to be largely crystalline and show a columnar structure with feather-like microstructure. For La-monazite, effective coatings between 10 and 500 micrometers in thickness can be deposited on substrates having temperatures between about 750&#xb0; C. and about 950&#xb0; C.

Monazite-based thermal barrier coatings

A method of joining a ceramic matrix composite rocket nozzle to a metal manifold is provided, wherein a silicon nitride insert is disposed inside the ceramic matrix composite rocket nozzle and the metal manifold to provide a joint therebetween. The silicon nitride insert is preferably co-processed with the ceramic matrix composite rocket nozzle such that the ceramic matrix provides a bond between the rocket nozzle and the insert. The metal manifold is then secured to the silicon nitride insert, preferably using brazing, to form a joint assembly.

Method of joining ceramic matrix composites and metals

Monazite or xenotime-based blanket coatings that stiffen ceramic fabrics without causing embrittlement at temperatures of at least as high as 2400&deg; F. are provided. Methods for making the coatings are also provided. The methods comprise the synthesis of high purity, monazite and xenotime powders with the stoichiometric ratio of metal to phosphorous of about 1:1.

Monazite-based coatings for thermal protection systems

A woven preform for a ceramic composite has a plurality of layers and structural members. The plurality of layer are of woven yarns of fibrous material. The structural members extend between the layers. The layers and members define interlayer spaces. One or more of the layers may have a plurality of openings extending therethrough. Low density ceramic insulation made be deposited in the interlayer spaces via a slurry that enters the preform, or the preform after it has been made a part of a composite, through the openings. The carrier of the slurry exits the preform, leaving the randomly packed fibers in the interlayer spaces. The structural members may be walls that, along with the layers, define channels. The channels may be used to direct fluid through so as the composite functions as an insulator. The channels may be directed in the warp direction for achieving increased benefits.

Integrally woven ceramic composites

Thermodynamically stable ceramic composites are provided for use in high temperature reactive environments. A phosphate selected from monazites and xenotimes functions as a weak bond material in the composite. Monazite comprises a family of minerals having the form MPO.sub.4, where M is selected from the larger trivalent rare earth elements of the lanthanide series (La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, and Tb) and coupled substituted divalents and tetravalents such as Ca or Sr with Zr or Th. Xenotimes are phosphates similar to monazite where M is selected from Sc, Y, and the smaller trivalent rare earth elements of the lanthanide series (Dy, Ho, Er, Tm, Yb, and Lu). High temperature ceramic composites that include monazite or xenotime and exhibit damage tolerant behavior or non-catastrophic fracture may be fabricated in a variety of material systems and reinforcement morphologies, including multilayered laminar composites; fiber, whisker, and particulate reinforced composites; hybrid laminar composites; and fabric or fiber preform composites. In preferred embodiments, the ceramic matrix comprises a material similar to the reinforcement to improve compatibility of the composite materials. The weak bond material allows debonding and 'frictional' sliding between the constituents of the composite and inhibits crack growth across the interface.

Fibrous composites including monazites and xenotimes

Thermodynamically stable ceramic composites are provided for use in high temperature oxidizing environments. A phosphate selected from monazites and xenotimes functions as a weak bond interphase material between the constituents of the composites. Monazite comprises a family of minerals having the form MPO.sub.4, where M is selected from the larger trivalent rare earth elements of the lanthanide series (La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, and Tb) and coupled substituted divalents and tetravalents such as Ca or Sr with Zr or Th. Xenotimes are phosphates similar to monazite where M is selected from Sc, Y, and the smaller trivalent rare earth elements of the lanthanide series (Dy, Ho, Er, Tm, Yb, and Lu). High temperature ceramic composites that include monazite or xenotime and exhibit damage tolerant behavior or non-catastrophic fracture may be fabricated in a variety of material systems and reinforcement morphologies, including multilayered laminar composites; fiber, whisker, and particulate reinforced composites; and hybrid laminar composites. Alumina fibers may be used in single crystal or polycrystalline form as a reinforcement material. In preferred embodiments, the ceramic matrix comprises a material similar to the reinforcement to improve compatibility of the composite materials. The interphase material allows debonding and 'frictional' sliding between the constituents of the composite and inhibits crack growth across the interface.

Ceramic composites having a weak bond material selected from monazites

A magnetic switch for recording the change in position of a magnetic field includes a first object on which is positioned a source of magnetic force for creating a magnetic field and a second object on which is positioned at least one type II superconducting medium. The type II superconducting medium exhibits a permanent magnetic component after exposure to a magnetic field, such that relative motion between the first object and the second object causes the magnetic field to induce a residual magnetization in the superconducting medium. A device for sensing the direction of a magnetic field includes a first type II superconducting medium adapted to exhibit a permanent magnetic component after exposure to a magnetic field having a first direction, a second type II superconducting medium adapted to exhibit a permanent magnetic component after exposure to a magnetic field having a second direction orthogonal to the first direction, and a third type II superconducting medium adapted to exhibit a permanent magnetic component after exposure to a magnetic field having a third direction orthogonal to the first and second directions.

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Thousand Oaks, CA, United States of America

David Bruce Marshall