General Electric Company

Ctl Aerospace, Inc.

Nathan Carl Sizemore

Nolan Leander Cousineau

Kirk Douglas Gallier

Steven Robert Hayashi

Daniel Gene Dunn

Douglas Melton Carper

Jared Hogg Weaver

Douglas Glenn Decesare

Mackenzie Christopher Hock

Simeon Copple

Tyler Weber

Joseph Fackey

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

Methods for preparing ceramic products using liquid infusion technology and products formed from the same are provided. The methods and products include the incorporation of a particulate material and binder between ceramic fibers such that the fibers may be properly spaced during formation of the ceramic product. Ceramic matrix composite products can thereby be provided using near net shaping methods.

Liquid infusion molded ceramic matrix composites and methods of forming the same

A porous tool includes a mold body and an additively-manufactured film attached to a surface of the mold body. The film includes a porous layer and a nonporous support layer. The porous layer may include a surface having an array of surface pore openings, a network of interconnected passages in fluid communication with the surface pore openings, and one or more lateral edges that have an array of edge pore openings in fluid communication with the interconnected passages. Methods of forming a porous tool include depositing additive material on a build surface using a directed energy deposition system to form a film while simultaneously subtracting selected portions of the additive material from the film using laser ablation. Methods of forming a molded component include conforming a moldable material to a shape using a porous tool that includes a mold body and an additively-manufactured film, and evacuating outgas from the moldable material through a porous layer of the film.

Porous tools and methods of making the same

Ply layups and methods for forming composite components are provided. For example, a method for forming a composite component comprises laying up a plurality of composite plies to form a composite ply layup; partially processing the composite ply layup to form a green state layup; machining the green state layup; assembling the green state layup with one or more sub-assemblies; and processing the green state layup and the one or more sub-assemblies to form the composite component. In an exemplary embodiment, the composite component is a turbine nozzle airfoil. Another exemplary method comprises laying up a plurality of composite plies to form a composite ply layup; compacting the composite ply layup to form a green state layup; machining the green state layup; assembling the green state layup with one or more sub-assemblies; and processing the green state layup and the one or more sub-assemblies to form the composite component.

Shaped composite ply layups and methods for shaping composite ply layups

A method of making a rub strip includes resin transfer molding an arcuate composite structure. The resin transfer molding step includes inserting a honeycomb core into a mold cavity having an arcuate base so that the honeycomb core assumes an arcuate shape. The resin transfer molding step further includes directing liquid resin into the mold cavity to form the composite structure comprising the liquid resin and the honeycomb core, and curing the liquid resin for a sufficient period of time. The resin transfer molding step further includes removing the composite structure from the mold. The method further includes repeating the resin transfer molding step until a sufficient number of arcuate composite structures are produced. The method further includes coupling a plurality of the arcuate composite structures together to form the rub strip.

Growing community of inventors

Hamilton, OH, United States of America

Nathan Carl Sizemore