Siemens Westinghouse Power Corporation

Siemens Power Generation, Inc.

Siemens Energy, Inc.

Steven C Butner

Jay Alan Morrison

Jay Edgar Lane

Gary Brian Merrill

Harry A Albrecht

Yevgeniy P Shteyman

Robert William Kreutzer

Scott M Widrig

Christian X Campbell

Andrew Szweda

Yevgeuiy Shteyman

Yevgenly Shteyman

A ceramic matrix composite (CMC) material () with increased interlaminar strength is obtained without a corresponding debit in other mechanical properties. This is achieved by infusing a diffusion barrier layer () into an existing porous matrix CMC to coat the exposed first matrix phase () and fibers (), and then densifying the matrix with repeated infiltration cycles of a second matrix phase (). The diffusion barrier prevents undesirable sintering between the matrix phases and between the second matrix phase and the fibers during subsequent final firing and use of the resulting component () in a high temperature environment.

CMC with multiple matrix phases separated by diffusion barrier

A composite material () formed of a ceramic matrix composite (CMC) material () protected by a ceramic insulating material (). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material () may be used in the insulating material in order to avoid degradation of the fabric () of the CMC material during the co-firing step.

Methods of manufacturing insulated ceramic matrix composite

Insulated ceramic matrix composite and method of manufacturing

A method of manufacturing a composite structure uses a layer of an insulating material () as a mold for forming a substrate of a ceramic matrix composite (CMC) material (). The insulating material may be formed in the shape of a cylinder () with the CMC material wound on an outer surface () of the cylinder to form a gas turbine combustor liner (). Alternatively, the insulating material may be formed in the shape of an airfoil section () with the CMC material formed on an inside surface () of the insulating material. The airfoil section may be formed of a plurality of halves () to facilitate the lay-up of the CMC material onto an easily accessible surface, with the halves then joined together to form the complete composite airfoil. In another embodiment, a box structure () defining a hot gas flow passage () is manufactured by forming insulating material in the shape of opposed airfoil halves () joined at respective opposed ends by platform members (). A layer of CMC material () is then formed on an outside surface of the insulating material. A number of such composite material box structures are then joined together to form a vane ring () for a gas turbine engine.

Composite structure formed by CMC-on-insulation process

A multi-layer ceramic matrix composite structure ( ) having a plurality of fiber-reinforced cooling passages ( ) formed therein. The cooling passages are formed by the removal of a fugitive material ( ). The fugitive material is part of a wrapped fugitive material structure ( ) containing a layer of reinforcing ceramic fibers ( ) that is used to lay-up the multi-layer structure. An intermediate layer of ceramic fabric may be placed alternately over and under the wrapped fugitive material structure to separate the cooling passages into alternating upper ( ) and lower ( ) cooling passages. The transversely oriented fibers surrounding the cooling passages serve to increase the interlaminar strength of the structure when compared to prior art designs. An airfoil member ( ) incorporating such reinforced integral cooling passages ( ) is provided.

Ceramic matrix composite structure having integral cooling passages and method of manufacture

A ceramic matrix composite material (CMC) vane for a gas turbine engine wherein the airfoil member ( ) and the platform member ( ) are formed separately and are then bonded together to form an integral vane component ( ). Airfoil member and the platform member may be bonded together by an adhesive ( ) after being fully cured. Alternatively, respective joint surfaces ( ) of the green body state airfoil member and platform member may be co-fired together to form a sinter bond ( ). A mechanical fastener ( ) and/or a CMC doubler ( ) may be utilized to reinforce the bonded joint ( ). A matrix infiltration process ( ) may be used to create or to further strengthen the bond.

Ceramic matrix composite turbine vane

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San Marcos, CA, United States of America

Steven C Butner