WO2019194860A2 - Matériau cmc 3d pourvu d'une couche de protection thermique - Google Patents

Matériau cmc 3d pourvu d'une couche de protection thermique Download PDF

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Publication number
WO2019194860A2
WO2019194860A2 PCT/US2018/051276 US2018051276W WO2019194860A2 WO 2019194860 A2 WO2019194860 A2 WO 2019194860A2 US 2018051276 W US2018051276 W US 2018051276W WO 2019194860 A2 WO2019194860 A2 WO 2019194860A2
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WIPO (PCT)
Prior art keywords
cmc
component
reinforcing fibers
cmc material
ceramic matrix
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PCT/US2018/051276
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English (en)
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WO2019194860A3 (fr
Inventor
Jay A. Morrison
Marco Claudio Pio Brunelli
Gary B. Merrill
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Siemens Aktiengesellschaft
Siemens Energy, Inc.
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Publication of WO2019194860A2 publication Critical patent/WO2019194860A2/fr
Publication of WO2019194860A3 publication Critical patent/WO2019194860A3/fr

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111—Fine ceramics
    • C04B35/117—Composites
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C04B35/185—Mullite 3Al2O3-2SiO2
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/44—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • C04B35/571—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide obtained from Si-containing polymer precursors or organosilicon monomers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/005—Selecting particular materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/284—Selection of ceramic materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
    • F23R3/00—Continuous combustion chambers using liquid or gaseous fuel
    • F23R3/007—Continuous combustion chambers using liquid or gaseous fuel constructed mainly of ceramic components
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5252—Fibers having a specific pre-form
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5268—Orientation of the fibers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/616—Liquid infiltration of green bodies or pre-forms
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • F01D9/023—Transition ducts between combustor cans and first stage of the turbine in gas-turbine engines; their cooling or sealings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/10—Stators
    • F05D2240/11—Shroud seal segments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/21—Oxide ceramics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced
    • F05D2300/6033—Ceramic matrix composites [CMC]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced
    • F05D2300/6034—Orientation of fibres, weaving, ply angle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/70—Treatment or modification of materials
    • F05D2300/702—Reinforcement
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
    • F23R2900/00—Special features of, or arrangements for continuous combustion chambers; Combustion processes therefor
    • F23R2900/00018—Manufacturing combustion chamber liners or subparts

Definitions

  • Disclosed embodiments are generally related to turbine engines and in particular to materials used in the construction of components for the turbine engines.
  • Gas turbine engines comprise a casing or cylinder for housing a compressor section, a combustion section, and a turbine section.
  • a supply of air is compressed in the compressor section and directed into the combustion section.
  • the compressed air enters the combustion inlet and is mixed with fuel.
  • the air/fuel mixture is then combusted to produce high temperature and high pressure (working) gas. This working gas then travels through the transition and into the turbine section of the turbine.
  • the turbine section typically comprises rows of vanes which direct the working gas to the airfoil portions of the turbine blades.
  • the working gas travels through the turbine section, causing the turbine blades to rotate, thereby turning a rotor attached thereto.
  • the rotor is also attached to the compressor section, thereby turning the compressor and is also operatively connected to an electrical generator for producing electricity.
  • High efficiency of a combustion turbine is improved by heating the gas flowing through the combustion section to as high a temperature as is practical.
  • the hot gas may degrade various metal turbine components, such as the combustor, transition ducts, vanes, ring segments, and turbine blades as it flows through the turbine.
  • High temperature resistant ceramic matrix composite (CMC) materials have been developed and increasingly utilized in gas turbine engines.
  • CMC materials include a ceramic or a ceramic matrix material, either of which hosts a plurality of fibers.
  • the fibers may have predetermined orientations to provide the CMC materials with additional mechanical strength.
  • fiber reinforced ceramic matrix composites are manufactured by the infiltration of a matrix slurry (e.g., alumina, mullite, YAG, silicon-containing polymers, molten silicon, or the like) into a fiber preform, but can be manufactured in a variety of other ways.
  • a matrix slurry e.g., alumina, mullite, YAG, silicon-containing polymers, molten silicon, or the like
  • Most commercially available oxide ceramic fibers and their respective oxide-matrix CMCs are temperature limited for long life applications and, therefore, should be cooled to enable operation at temperatures exceeding this limit.
  • a thermal barrier coating TBC
  • TBC thermal barrier coating
  • aspects of the present disclosure relate to providing a CMC material that has improved capability to withstand degradation that occurs during operation of the gas turbine engine.
  • An aspect of the present disclosure comprises a component formed with a 3D CMC material, wherein the 3D CMC material comprises: an outer surface of the ceramic matrix material, wherein the outer surface is part of a thermal protective layer that is 10-50% of a total 3D CMC thickness; an inner surface of the ceramic matrix material; and reinforcing fibers extending throughout the ceramic matrix material, wherein the reinforcing fibers extend unitarily or interconnectedly from the outer surface to the inner surface, and wherein the outer surface does not have a thermal barrier coating.
  • Another aspect of the present disclosure may comprise a component formed with a 3D CMC material, wherein the 3D CMC material comprises: an outer surface formed of ceramic matrix material, wherein the outer surface is part of a thermal protective layer that is 10-50% of a total 3D CMC thickness; an inner surface formed of the ceramic matrix material; reinforcing fibers extending throughout the ceramic matrix material, wherein the reinforcing fibers extend unitarily or interconnectedly from the outer surface to the inner surface; and first fibers and second fibers embedded in the ceramic matrix material, wherein the first fibers and the second fibers do not extend unitarily or interconnectly from the outer surface to the inner surface, and wherein the outer surface does not have a thermal barrier coating.
  • Still yet another aspect of the present disclosure may comprise a 3D CMC material.
  • the 3D CMC material may have an outer surface of ceramic matrix material, wherein the outer surface is part of a thermal protective layer that is 10-50% of a total 3D CMC thickness, an inner surface of the ceramic matrix material; and reinforcing fibers extending throughout the ceramic matrix material, wherein the reinforcing fibers extend unitarily or interconnectedly from the outer surface to the inner surface.
  • Fig. 1 is a diagram of a 2D CMC material having a thermal barrier coating.
  • Fig. 2 is a graph illustrating the strength of the 2D CMC material.
  • Fig. 3 is a diagram of a 3D CMC material having a reinforcing fiber extending unitarily from an outer surface to an inner surface.
  • Fig. 4 is a flow chart setting forth the method for forming a 3D CMC material.
  • Fig. 5 is a diagram of a 3D CMC material further illustrating the thermal protective layer.
  • Fig. 6 is another graph illustrating the strength of the 3D CMC material.
  • Fig. 7 is a diagram illustrating a layer-to-layer angled weave.
  • Fig. 8 is a diagram illustrating a braided weave.
  • Components in gas turbine engines may be made of a two-dimensional (2D) CMC material.
  • Prior Art Fig. 1 shows a section of a component 1 formed with a conventional 2D CMC material 2.
  • the 2D CMC material 2 is made of fibers 4 located within a ceramic matrix material 6.
  • the 2D CMC material 2 is formed of layers 5 that may be stacked on top of each other.
  • the top layer of the 2D CMC material 2 may have a thermal barrier coating (TBC) 7 sprayed thereon.
  • TBC thermal barrier coating
  • the thermal barrier coating is typically a material such as yttria-stabilized-zirconia, mullite, YAG, alumina, etc.
  • Fig. 2 is a diagram illustrating the strength of the 2D CMC material 2.
  • the diagram illustrates that at certain temperatures and at certain radial thermal stresses the strength of the 2D CMC material 2 is insufficient. This can result in structural damage at too high a temperature.
  • the inventors recognized that using a material for the components that utilizes the existing CMC material as the heat protective layer may provide better protection for the component and extend its lifespan. However, using only layers to form a 2 dimensional structure can result in whole or partial delamination.
  • a three-dimensional (3D) 3D CMC material 12 is formed and used for the component.
  • 3D CMC material it is meant that the ceramic matrix material has a structure that is not limited to layers, but instead has reinforcing fibers 20 that extend either unitarily or interconnectedly from an outer surface 22 to an inner surface 23 of the 3D CMC material 12.
  • the 3D CMC material 12 may be formed by creating a weave of fibers 4 that can form planes 15. In addition to planes 15 having a weave of fibers 4 there is the added feature of the reinforcing fibers 20.
  • the fibers 4 and the reinforcing fibers 20 are located within a ceramic matrix material 6.
  • the 3D CMC material 12 is formed so that reinforcing fibers 20 pass from the outer surface 22 to the inner surface 23, through the planes 15.
  • the reinforcing fibers 20 shown in Fig. 2 are unitary in nature. This means that a single reinforcing fiber 20 moves from the outer surface 22 to the inner surface 23 without having to be interlocked with another reinforcing fiber 20.
  • the reinforcing fibers 20 may be an interconnected reinforcing fiber 20, such as illustrated by the weaves in Fig. 7 and Fig. 8.
  • the reinforcing fiber 20 is an interconnected reinforcing fiber, it means that the reinforcing fiber 20 may be woven and/or intertwined with another reinforcing fiber 20 so that there is a continuous interwoven chain extending from the outer surface 22 to the inner surface 23.
  • the reinforcing fiber 20 is a unitary or interconnected reinforcing fiber 20, the reinforcing fiber 20 provides enhanced structural integrity for the 3D CMC material 12. Unlike the simple plies that exist with 2D CMC materials, the reinforcing fibers 20 help inhibit shearing.
  • the reinforcing fibers 20 are oriented in such a manner that the dimension L of the reinforcing fiber 20 extends in a direction that is at an angle with respect to the outer surface 22 of the 3D CMC material 12. As discussed above, the reinforcing fibers 20 help inhibit delamination of the CMC component 10.
  • the weave shown in Fig. 3 is an angle interlock weave.
  • the reinforcing fiber 20 passes through multiple planes 15.
  • Fig. 2 the reinforcing fiber 20 passes through all of the planes 15 of the 3D CMC structure 12.
  • the angle at which the reinforcing fiber 20 is oriented with respect to the outer surface 22 of the 3D CMC material 12 is a 45° angle.
  • a 45° angle is shown, it should be understood that an angle within the range of l0°-90° would be effective with the use of the reinforcing fiber 20.
  • the reinforcing fiber 20 weaves its way from the outer surface 22 to the inner surface 23 multiple times. In weaving from the outer surface 22 to the inner surface 23, the orientation of the reinforcing fiber 20 changes direction from extending inwardly from the outer surface 22 through all the to then extending back towards the outer surface 22 of the 3D CMC structure 12.
  • a matrix slurry e.g., alumina, mullite, YAG, silicon-containing polymers, molten silicon, or the like
  • a matrix slurry is infiltrated into a fiber preform. While this is one manner in which the 3D CMC material 12 may be manufactured there are other manners in which the 3D CMC material 12 may be made.
  • Fig. 4 shows a flow chart illustrating an embodiment of a process for the manufacture of the 3D CMC material 12 shown in Fig. 3.
  • the fibers 4 are manufactured or otherwise provided.
  • the reinforcing fibers 20 are woven through the matrix of fibers 4 using a near net shape (NNS) preform weaving or braiding operation. The weaving of the fibers 4 and the reinforcing fibers 20 form a preform that will then be infiltrated with a ceramic matrix material 6.
  • NPS near net shape
  • step 106 the preform is then infiltrated with the ceramic matrix material 6.
  • step 108 the preform is compacted. Steps 106 and 108 may be reversed in some processes.
  • step 110 the matrix is dried or cured to a“green” state.
  • step 112 the green preform is fired. The firing of the preform solidifies the preform.
  • step 114 the fired preform may undergo an additional step of infiltrating or otherwise coating of a vapor resistant layer (VRL). Optionally, this VRL may be applied prior to final firing and after a bisque-firing step.
  • VRL vapor resistant layer
  • an intermediate temperature treatment to enhance and improve the rate of degradation resulting from high pressure moisture attack may optionally be applied in the formation of the 3D CMC material 12.
  • the gradual recession of alumina and alumina/silicate composition can be can be improved by the addition of certain rare earth oxides that have been shown to substantially slow the recession rates of such chemical species. Such constituents are described in US Patent No. 9,328,028, herein incorporated by reference.
  • Such examples include but are not limited to: pyrochlore structures; HfSi0 4 ; ZrSi0 4 ; Y2S12O7; Y2O3; Zr02, Hf02; yttria and/or ZrCtefully or partially stabilized by rare earth elements; yttria and/or HfCh partially or fully stabilized by rare earth elements, yttria and/or ZrCh/HfCh partially or fully stabilized by rare earth elements; yttrium aluminum garnet; rare earth silicates of the form RE2S12O7; rare earth oxides of the form RE2O3; rare earth zirconates or hafnates of the form REhZnO ⁇ or RE 4 Hf 3 0i2, wherein the rare earth elements may be one or more of the following: Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu.
  • a functionally graded concentration may be applied through the application of a specifically prepared slurry at intermediate sintering temperatures to improve the recession behavior of the outer surface 22 of the 3D CMC material 12, especially when exposed to high velocity combustion gases in excess of 1200 °C.
  • VPL vapor resistive layer
  • FIG. 5 there is a diagram of the 3D CMC material 12 having a thermal protective layer 24 in accordance with an aspect of the present invention.
  • the thermal protective layer (TPL) 24 is formed in the uppermost planes 15 of the 3D CMC material 12.
  • the TPL 24 comprises the outer surface 22 and portions of the 3D CMC material 12 beneath the outer surface 22. This may include one or more planes 15 in those embodiments that have identifiable planes 15. In those embodiments that are formed with a more complex weave or braiding of reinforcing fibers 20, such as shown in Figs. 7 and 8, the top millimeter of formed material may act as the thermal protective layer 24.
  • the TPL 24 is between 10-50% of the total 3D CMC thickness.
  • the thickness (T) of the 3D CMC material 12 is the shortest distance from a point on the outer surface 22 to the inner surface 23.
  • the 3D CMC material 12 may be subjected to a temperature exceeding the maximum temperature limit for the component and applying cooling to achieve a thermal gradient, wherein the TPL 24 exceeds this temperature limit, but the bulk of the 3D CMC material 12 remains below the temperature limit.
  • the thermal protective layer 24 functions as a non- structural or semi-structural layer.
  • the thermal protective layer 24 protects the underlying layers without the need for having a thermal barrier coating.
  • the TPL 24 may be infused with a rare earth oxide as described above to protect from moisture-related recession. This forms a TPL 24 that is also a VPL.
  • the 3D CMC material 12 When the 3D CMC material 12 is exposed to surface temperatures greater than 1200 °C but is also cooled, a thermal gradient can be achieved such that the 3D CMC material 12 below the TPL 24 remains below 1200 °C, or whatever the maximum temperature of the CMC component 10 is.
  • the threshold temperature limit of the CMC component 10 may be determined by the performance of mechanical property behaviour such as creep and thermo-mechanical fatigue. While the temperature of 1200 °C is discussed herein, it should be understood that it is in reference to one component 10. The temperature threshold may vary for different components 10 made of the 3D CMC material 12. The result is that the TPL 24 may be exposed to temperatures above the maximum threshold for the CMC component, while the 3D CMC material 12 below the TPL 24 remains below the maximum threshold temperature for the CMC component 10.
  • three layers 15 are indicated in Fig. 5; a first layer 17, a second layer 19, and a third layer 21.
  • the outer surface 22, the first layer 17, and the second layer 19 may function as the TPL 24.
  • the TPL 24 functions in a similar manner as a thermal barrier coating without the associated costs. Additionally, the TPL 24 provides additional protection from heat while not suffering from some issues associated with the use of TBCs, such as the delamination of planes of weakness of 2D.
  • the reinforcing fibers 20 improve the out of plane strength of the 3D CMC material 12.
  • Fig. 6 is a diagram illustrating the strength of the 3D CMC material 12.
  • the 3D CMC material 12 shows a strength margin even after thermal degradation.
  • Fig. 7 illustrates a layer-to-layer angled weave.
  • Fig. 8 is a diagram illustrating a braided weave.
  • 3D fiber architectures that may be used as well, for example orthotropic weaves, knitted or stitched structures, and the like.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un composant (10) comprenant une surface externe (22) en matériau composite à matrice céramique (12), la surface externe (22) faisant partie d'une couche de protection thermique (24) qui représente 10-50% de l'épaisseur CMC 3D totale. Le composant comprend également une surface interne (23) de matériau composite à matrice céramique (12). Des fibres de renforcement (20) s'étendent dans la masse du matériau composite à matrice céramique (12), les fibres de renforcement (20) s'étendant de manière unitaire ou interconnectée de la surface externe (22) jusqu'à la surface interne (23).
PCT/US2018/051276 2017-09-27 2018-09-17 Matériau cmc 3d pourvu d'une couche de protection thermique WO2019194860A2 (fr)

Applications Claiming Priority (2)

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US201762563908P 2017-09-27 2017-09-27
US62/563,908 2017-09-27

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WO2019194860A2 true WO2019194860A2 (fr) 2019-10-10
WO2019194860A3 WO2019194860A3 (fr) 2020-02-20

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114671675A (zh) * 2022-04-29 2022-06-28 哈尔滨工业大学 一种具有小晶粒尺寸的抗cmas腐蚀的高熵陶瓷材料及其制备方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9328028B2 (en) 2008-07-22 2016-05-03 Siemens Energy, Inc. Structure and method for protecting a hybrid ceramic structure from moisture attack in a high temperature environment

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6610385B2 (en) * 2001-12-20 2003-08-26 General Electric Company Integral surface features for CMC components and method therefor
US7247212B2 (en) * 2004-12-21 2007-07-24 General Electric Company Orthogonal weaving for complex shape preforms
US8272843B1 (en) * 2005-09-12 2012-09-25 Florida Turbine Technologies, Inc. TBC with fibrous reinforcement
US8357323B2 (en) * 2008-07-16 2013-01-22 Siemens Energy, Inc. Ceramic matrix composite wall with post laminate stitching

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9328028B2 (en) 2008-07-22 2016-05-03 Siemens Energy, Inc. Structure and method for protecting a hybrid ceramic structure from moisture attack in a high temperature environment

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114671675A (zh) * 2022-04-29 2022-06-28 哈尔滨工业大学 一种具有小晶粒尺寸的抗cmas腐蚀的高熵陶瓷材料及其制备方法
CN114671675B (zh) * 2022-04-29 2022-10-25 哈尔滨工业大学 一种具有小晶粒尺寸的抗cmas腐蚀的高熵陶瓷材料及其制备方法

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