Rtx Corporation

Raytheon Technologies Corporation

United Technologies Corporation

Kathryn S Read

Andrew Joseph Lazur

Ying She

Thomas E Clark

Mary Colby

William M Barker

James Thompson Beals

Raymond C Surace

Jon E Sobanski

Xia Tang

Mario P Bochiechio

Olivier H Sudre

Tania Bhatia Kashyap

John D Riehl

Richard Wesley Jackson

Daniel J Whitney

Michael G Abbott

Jeremy R Hart

Howard J Liles

John E Holowczak

David Wasserman

Jonas S Banhos

Christopher J Hertel

Richard Wesley Jackson, Iii

Russell Kim

Brendan M Lenz

Christian X Campbell

Winston Gregory Smiddy

Elisa M Zaleski

Alyson T Burdette

R Wesley Jackson

Nitin Garg

Sarah A Frith

John H Shaw

Cristal Chan

Aaron Tomich

Kenneth Petroski

Olivier Hl Sudre

Disclosed herein is a composite tow comprising a plurality of ceramic filaments; one or more sacrificial yarn filaments; where the sacrificial yarn filaments are operative to undergo decomposition or melting upon being subjected to an elevated temperature; and wherein the sacrificial yarn filaments leave open spaces in the tow upon being subjected to decomposition, dissolution or melting; where the filaments have an average filament diameter of 5 to 15 micrometers.

Sacrificial yarn filament for use in ceramic matrix composites, methods of manufacture thereof and articles comprising the same

A component includes fabric layers of ceramic matrix composite ('CMC') fabric. The fabric has layers separated by an insert formed of the CMC fabric. The insert has at least one tapered end. The tapered end has a thickness which is less than a central thickness of the insert. A method is also disclosed.

Gas turbine engine component formed by CMCS and having a compressed insert with tapered ends

A method of forming a ceramic matrix composite component includes forming a fiber preform, the fiber preform including a plurality of ceramic fiber plies, a non-reduced fiber region having an areal weight, and a reduced fiber region characterized by a reduced areal weight less than the areal weight of the non-reduced fiber region by at least 5 percent. The method further includes selectively applying ceramic particles to the reduced fiber region in such manner as to avoid applying the ceramic particles to the non-reduced fiber region, and subsequently densifying the preform.

Localized particle additions to reduce defects in ceramic matrix composites caused by complex geometry preforming

A method for forming ceramic matrix composite (CMC) component includes forming a fiber preform, positioning the fiber preform into a chemical vapor infiltration reactor chamber, and densifying the fiber preform. Densification includes infiltrating the fiber preform with a first gas comprising precursors of silicon carbide and infiltrating the fiber preform with a second gas comprising a first rare earth element, wherein the steps of infiltrating the fiber preform with the first gas and infiltrating the fiber preform with the second gas are conducted simultaneously to produce a first rare earth-doped silicon carbide matrix in a first region of the component.

Doped silicon carbide ceramic matrix composite

A method of preparing a ceramic fabric and ceramic matrix composite components constructed from the ceramic fabric include transforming ceramic tows, or ceramic fabrics, to varying degrees from a first tow geometry to a second tow geometry, thereby reducing a first dimension of the ceramic tows and increasing a second dimension of the ceramic tows orthogonal to the first dimension. Plies constructed with flattened tows, or as-received tows, have various inter-tow pore sizes that are arranged with increasing inter-tow pore size towards exterior surfaces of the preform structure.

Gradient tow ribbonizing for chemical vapor infiltration ceramic matrix composites

A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region.

Self-healing matrix for a ceramic composite

A method of spreading fiber tows includes applying a coupling medium to a surface of a fibrous structure, positioning an ultrasonic probe adjacent to the surface of a fibrous structure, such that a tip of the ultrasonic probe is in contact with the coupling medium, moving at least one of the ultrasonic probe and the fabric structure relative to the other of the ultrasonic probe and the fibrous structure according to a first pattern, and imparting ultrasonic vibration with the ultrasonic probe to the surface of the fibrous structure while moving the ultrasonic probe along the surface of the fibrous structure. Imparting ultrasonic vibration to the surface of the fibrous structure spreads tows of the fibrous structure.

Fabric structure control using ultrasonic probe

A space filler for forming a fibrous preform may comprise an additively manufactured ceramic material. The additively manufactured ceramic material may define a plurality of pores. A shape of the additively manufactured ceramic material may complement a shape of a void formed by fibrous regions of the fibrous preform.

Porous space fillers for ceramic matrix composites

An airfoil includes an airfoil section that has an airfoil wall that circumscribes an internal airfoil cavity and defines leading and trailing ends and pressure and suction sides. The airfoil wall is formed of a ceramic matrix composite (CMC) laminate comprised of fiber plies disposed in a ceramic matrix. The fiber plies include a skin fiber ply that defines an exterior of the airfoil section and at least one inner fiber ply that lines the skin fiber ply. At least one inner fiber ply locally terminates at one of the leading end or the trailing end such that the airfoil wall has fewer of the fiber plies in the leading end or the trailing end than in each of the pressure side and the suction side.

CMC laminate airfoil with ply drops

A fiber-reinforced component for use in a gas turbine engine includes a first braided fiber sleeve forming a cooling channel and a plurality of fiber plies enclosing the first braided fiber sleeve, with the plurality of fiber plies forming first and second walls separated by the first braided fiber sleeve. The fiber-reinforced component further includes a matrix material between fibers of the braided fiber sleeve and the plurality of fiber plies.

CMC component with integral cooling channels and method of manufacture

A method of preparing a ceramic fabric for use in a ceramic matrix composite includes transforming a ceramic tow from a first tow geometry to a second tow geometry, thereby reducing a first dimension of the ceramic tow and increasing a second dimension of the ceramic tow orthogonal to the first dimension to produce a flattened tow. The method includes weaving or braiding the flattened ceramic tow to form a ceramic fabric.

Ribbonized tows for optimized improved composite performance

A tooling assembly suitable for use in infiltrating a fibrous preform comprises an outer tooling fixture with a plurality of outer sidewalls defining an inner volume, each of the plurality of outer sidewalls having an outer wall thickness, and a window extending through the outer wall thickness of at least one outer sidewall of the plurality of sidewalls. The tooling assembly further comprises an inner tooling fixture positioned within the inner volume of the outer tooling fixture, the inner tooling having a plurality of inner sidewalls, each of the plurality of inner sidewalls having an inner wall thickness, and a plurality of holes extending through the inner wall thickness of at least one inner sidewall of the plurality of inner sidewalls. The at least one outer sidewall is positioned adjacent the at least one inner sidewall such that the window overlaps with at least a subset of the plurality of holes in the at least one inner sidewall.

Minimization of chemical vapor infiltration tooling hole length through windows

A method of forming a vane preform includes braiding a sleeve from ceramic fibers, inserting a flared mandrel into the sleeve, the flared mandrel comprising a body region and at least one contoured region, manipulating the sleeve using the flared mandrel to form contours in the sleeve corresponding to the contoured region of the flared mandrel, and laying up at least one ceramic ply with the sleeve to form the vane preform.

Flared mandrel and process for effective use in transition regions

A ceramic matrix composite includes a plurality of ceramic fibers and an interface coating disposed on the plurality of ceramic fibers. The interface coating includes a carbon-based layer disposed on each ceramic fiber of the plurality of ceramic fibers and a boron-nitride based layer disposed on the first carbon-based layer. The ceramic matrix composite also includes a ceramic matrix surrounding the plurality of ceramic fibers. A ceramic matrix composite and a method of forming a ceramic matrix composite component are also disclosed.

Ceramic component

A method of forming a ceramic matrix composite includes applying a tackifier of ethanol and 3% to 12% polyvinyl butyral to a ceramic material, removing the ethanol from the ceramic material, and removing the polyvinyl butyral. The step of applying the tackifier includes one of a spraying, pipetting, painting, and immersing technique.

Growing community of inventors

Marlborough, CT, United States of America

Kathryn S Read