Rolls-royce Corporation

Paul A Doleman

Edwin G Butler

Anthony G Razzell

Clive B Ponton

Stephen Mason

John Dominy

Trevor J Illston

Peter M Marquis

Reza Piramoon

Mark J Gilbert

Gary B Merrill

Michael J Percival

Ihsan Ai-i Al-Dawery

Ihsan A H Al-Dawery

A method of manufacturing a ceramic matrix composite comprises forming a slurry comprising a ceramic sol, filler particles and a solvent and forming laminates of fibers ( ). The laminates of fibers ( ) are impregnated with the slurry and are stacked ( ) on a mold ( ). The stack ( ) of laminates of fibers ( ) is covered by a porous membrane ( ), a breather fabric ( ) and a vacuum bag ( ). The vacuum bag ( ) is evacuated and is heated to a temperature of 60&deg; C. for 10 hours to produce a ceramic matrix composite. The ceramic matrix composite is then heated to a temperature of 1200&deg; C. at atmospheric pressure to sinter the ceramic matrix composite.

Method of manufacturing a ceramic matrix composite

A method of manufacturing a ceramic matrix composite comprises forming a slurry comprising a ceramic sol, filler particles and a solvent and forming laminates of fibres ( ). The laminates of fibres ( ) are impregnated with the slurry and are stacked ( ) on a mould ( ). The stack ( ) of laminates of fibres ( ) is covered by a porous membrane ( ), a breather fabric ( ) and a vacuum bag ( ). The vacuum bag ( ) is evacuated and is heated to a temperature of 60&deg; C. for 10 hours to produce a ceramic matrix composite. The ceramic matrix composite is then heated to a temperature of 1200&deg; C. at atmospheric pressure to sinter the ceramic matrix composite.

An abradable seal comprises a plurality of hollow aluminosilicate spheres in a matrix of aluminium phosphate. The matrix of aluminium phosphate also has an aluminosilicate filler. The hollow aluminosilicate spheres have a diameter in the range of 400 to 1800 microns, preferably a diameter in the range of 800 to 1400 microns. The weight proportion of hollow aluminosilicate spheres in the abradable seal is 30% to 50%. The density of the abradable seal is 1.5 grams per cubic centimeter. The hollow aluminosilicate spheres in the aluminium phosphate matrix have a relatively high temperature capability of approximately 1300.degree. C. maximum. This makes the abradable seal better able to withstand the environment in the turbine of a turbofan gas turbine engine.

Abradable composition, a method of manufacturing an abradable

An abradable seal comprises a plurality of hollow aluminosilicate spheres in a matrix of aluminium phosphate. The matrix of aluminium phosphate also has an aluminosilicate filler. The hollow aluminosilicate spheres have a diameter in the range of 400 to 1800 microns, preferably a diameter in the range of 800 to 1400 microns. The weight proportion of hollow aluminosilicate spheres in the abradable seal is 30% to 50%. The density of the abradable seal is 1.5 grammes per cubic centimetre. The hollow aluminosilicate spheres in the aluminium phosphate matrix have a relatively high temperature capability of approximately 1300.degree. C. maximum. This makes the abradable seal better able to withstand the environment in the turbine of a turbofan gas turbine engine.

A method of manufacturing a composite material in which a fibre matt is placed adjacent a plate electrode in ceramic sol. The application of an electric field to the sol via the electrode results in the deposition of sol particles on the electrode which subsequently permeate the fibre matt. The permeated fibre matt is then removed from the sol, dried out and heated to sinter the sol particles.

Method of manufacturing a composite material

The mechanical behavior of a given component formed from reinforcing ceramic fibers enclosed in a ceramic matrix is determined by subjecting a dummy component to mechanical testing. The dummy component is formed from low modulus organic resin fibers enclosed in a matrix of an organic resin having a correspondingly low modulus. The organic resin fibers have the same configuration and fiber architecture as those of the ceramic fibers.

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Derby, United Kingdom

Paul A Doleman