Compliant composite component and method of manufacture

A composite component includes a bonded portion and a component mount. The component mount is coupled to the bonded portion to move relative to the bonded portion. The bonded portion includes a fiber portion and a ceramic portion.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to composite materials, and more specifically to attachment methods of composite materials.

BACKGROUND

Design of gas turbine engines is driven by many concerns, however, maximizing engine efficiency to minimize costs of operation and environmental impact due to emissions are becoming increasingly important. Gas turbine efficiency is maximized by increasing a maximum operating temperature of the gas turbine engine. As a result, efficiency is limited by the temperature capabilities hot components such as turbine blades, turbine vanes, turbine blade tracks, combustor liners, etc.

Temperature capabilities of hot components may be increased through cooling, materials, and coatings of the components. Some materials, such as nickel-based (Nibased) superalloys have reached an intrinsic limit in high-temperature resistance. As a result, development has focused on Thermal Barrier Coatings (TBC), which may be brittle, and Ceramic Matrix Composite (CMC) materials, which sometimes suffer from load transfer problems.

CMC materials include various components which may include Silicon and Carbide. In one example, SiC/SiC CMC materials may be used in hot section structural components for generation gas turbine engines. SiC/SiC CMC engine components provide desirable high-temperature mechanical properties, high-temperature physical properties, and chemical properties. These desirable properties allow gas turbine engines to operate at relatively higher temperatures than the current engines having superalloy components. SiC/SiC CMC materials also provide the additional benefit of damage tolerance, which monolithic ceramic materials do not possess.

However, combining CMC materials with metal materials has some issues. One issue is that CMC materials often have a different stiffness than metal components in which the CMC materials may be joined to. Another issue is that CMC materials have different Coefficients of Thermal Expansion (CTE) than metal materials they may be joined to. As a result, significant stresses may be result where CMC materials are joined to non-CMC materials.

SUMMARY

A composite component may include a bonded portion and an un-bonded portion. The bonded portion may be made from a ceramic matrix composite material. The un-bonded portion may be made from the ceramic composite material. The un-bonded portion may be coupled to the bonded portion to move relative to the bonded portion in response to application of a load to cause the composite component to deform in a controlled manner without fracture of the composite component.

In some embodiments, the un-bonded portion may include a first un-bonded section, a second un-bonded portion, and a third un-bonded portion. The first un-bonded portion may be coupled to the bonded portion to move relative to the bonded portion in response to application of the load. The second un-bonded section may be coupled to the bonded portion to move relative to the bonded portion and the first un-bonded section in response to application of the load. The third un-bonded section may be coupled to the bonded portion to move relative to the bonded portion, the first un-bonded section, and the second un-bonded section in response to application of the load.

In some embodiments, the third un-bonded section may be located between the bonded portion and the second un-bonded section. The second un-bonded section may be located between the third un-bonded section and the first un-bonded section.

In some embodiments, the composite component may have a load vs. deflection curve including, in series, a first segment, a second segment, a third segment, and a fourth segment. The first segment may be provided by the first un-bonded section and may have a first slope. The second segment may be provided by the second un-bonded section and may have a second slope. The third segment may be provided by the third un-bonded section and may have a third slope. The fourth segment may be provided by the bonded portion and may have a fourth slope.

In some embodiments, the second slope may be greater than the first slope. The third slope may be greater than the fourth slope. The fourth slope may be greater than the third slope.

In some embodiments, the un-bonded portion may include a first lower un-bonded section, a second lower un-bonded section, and a third lower un-bonded section. The first lower un-bonded section may be coupled to the bonded portion to move relative to the bonded portion in response to application of the load. The second lower un-bonded section may be coupled to the bonded portion to move relative to the bonded portion and the first lower un-bonded section in response to application of the load. The third lower un-bonded section may be coupled to the bonded portion to move relative to the bonded portion, the first lower un-bonded section, and the second lower un-bonded section in response to application of the load.

In some embodiments, the un-bonded portion may further includes a first upper un-bonded section, a second upper un-bonded section, and a third upper un-bonded section. The first upper un-bonded section may be coupled to the bonded portion to move relative to the bonded portion in response to application of the load. The second upper un-bonded section may be coupled to the bonded portion to move relative to the bonded portion and the first upper un-bonded section in response to application of the load. The third upper un-bonded section may be coupled to the bonded portion to move relative to the bonded portion, the first upper un-bonded section, and the second upper un-bonded section in response to application of the load.

In some embodiments, the bonded portion may include a first bonded section and a second bonded section. The second bonded section may be located between the third lower and upper un-bonded sections. The second upper un-bonded section may be located between the third upper un-bonded section and the first upper un-bonded section. The second lower un-bonded section may be located between the third lower un-bonded section and the first lower un-bonded section.

In some embodiments, the composite component may have a load vs. deflection curve including, in series, a first segment, a second segment, a third segment, and a fourth segment. The first segment may be provided by the first lower and upper un-bonded sections and may have a first slope. The second segment may be provided by the second lower and upper un-bonded sections and may have a second slope. The third segment may be provided by the third upper and lower un-bonded sections and may have a third slope. The fourth segment may be provided by the second bonded section and may have a fourth slope.

In some embodiments, the first slope may be greater than the second slope. The third slope may be greater than the second slope. The fourth slope may be greater than the second and the third slopes. The first slope and the fourth slope may be about equal.

In some embodiments, the composite component may further comprise a component mount coupled to the un-bonded portion. The component mount may be configured to apply the load which is a pre-loading of the un-bonded portion.

In some embodiments, the composite component may further comprise a component mount coupled to the un-bonded portion. The load may include a first force and a second force. The first force may be applied by the component mount to the un-bonded portion. The second force may be applied to the bonded portion in a direction opposite the first force.

In some embodiments, the composite component may have a load vs. deflection curve including, in series, a first segment, a second segment, a third segment, a fourth segment, and a fifth segment. The first segment may be provided by the first lower and upper un-bonded sections and may have a first slope. The second segment may be provided by the second lower and upper un-bonded sections and may have a second slope. The third segment may be provided by the third upper and lower un-bonded sections and may have a third slope. The fourth segment may be provided by the second bonded section and may have a fourth slope. The fifth section may be provided by the first, second, and third upper and lower sections and the bonded portion.

In some embodiments, the first slope may be greater than the second slope. The third slope may be greater than the second slope. The third slope may be greater than the second and the third slopes. The first and second slopes may be about equal. The fifth slope may be less than the second slope.

In some embodiments, the composite component may further comprise a component mount coupled to the un-bonded portion. The load may include a first force, a second force, and a third force. The first force may be applied to the un-bonded portion in a first direction by the component mount. The second force may be applied to the bonded portion in the first direction. The third force may be applied to the bonded portion in a second direction opposite the first direction.

In some embodiments, the bonded portion may include a first bonded section and a second bonded section. The second bonded section may be appended to the first bonded section to extend away from the first bonded section.

In some embodiments, the un-bonded portion may include a first un-bonded section, a second un-bonded section, and a third un-bonded section. The first un-bonded section may be appended to the second bonded section to move relative to the second bonded section in response to application of the load. The second un-bonded section may be appended to the second bonded section to move relative to the second bonded section and the first un-bonded section in response to application of the load. The third un-bonded section may be appended to the second bonded section to move relative to the second bonded section, the first un-bonded section, and the second un-bonded section in response to application of the load.

In some embodiments, the third un-bonded section may be coupled to the first bonded section to translate relative to the first bonded section. The third un-bonded section may be appended to the second bonded section to pivot relative to the second bonded section, the second un-bonded section, and the first un-bonded section.

In some embodiments, the second un-bonded section may be coupled to the third un-bonded section to translate relative to the third un-bonded section. The second un-bonded section may be appended to the second bonded section to pivot relative to the second bonded section, the third un-bonded section, and the first un-bonded section.

In some embodiments, the first un-bonded section may be coupled to the second un-bonded section to translate relative to the second un-bonded section, the third un-bonded section, and second bonded section. The first un-bonded section may be appended to the second bonded section to pivot relative to the second bonded section, the second un-bonded section, and the third un-bonded section.

In some embodiments, the third un-bonded section may be located between the first bonded section and the second un-bonded section. The second un-bonded section may be located between the third un-bonded section and the first un-bonded section.

In some embodiments, the composite component may have a load vs. deflection curve including, in series, a first segment, a second segment, a third segment, and a fourth segment. The first segment may be provided by the first un-bonded section and may have a first slope. The second segment may be provided by the second un-bonded section and may have a second slope. The third segment may be provided by the third un-bonded section and may have a third slope. The fourth segment may be provided by the bonded portion and may have a fourth slope.

In some embodiments, the second slope may be greater than the first slope. The third slop may be greater than the fourth slope. The fourth slope may be greater than the third slope.

In some embodiments, the third un-bonded section may be located between the first bonded section and the second un-bonded section. The second un-bonded section may be located between the third un-bonded section and the first un-bonded section.

In some embodiments, the composite component may have a load vs. deflection curve including, in series, a first segment, a second segment, a third segment, and a fourth segment. The first segment may be provided by the first un-bonded section and may have a first slope. The second segment may be provided by the second un-bonded section and may have a second slope. The third segment may be provided by the third un-bonded section and may have a third slope. The fourth segment may be provided by the bonded portion and have a fourth slope.

In some embodiments, the second slope may be greater than the first slope. The third slope may be greater than the fourth slope. The fourth slope may be greater than the third slope.

In some embodiments, the composite component may further comprise a component mount. The component mount may be coupled to the un-bonded portion to move therewith. In some embodiments, the component mount may be a hinge.

In some embodiments, the composite component may have a load vs. deflection curve including, in series, a first segment and a second segment. The first segment may be provided by the un-bonded portion and may have a first slope. The second segment may be provided by the bonded portion and may have a second slope. The second slope may be greater than the first slope.

DETAILED DESCRIPTION OF THE DRAWINGS

A compliant composite component10in accordance with the present disclosure is shown, for example, inFIG. 1undergoing application of an increasing load12. The compliant composite component10includes a bonded portion14and an un-bonded portion16as shown inFIG. 1. The bonded portion14is made from a Ceramic Matrix Composite (CMC) material. In one example, the CMC material is a laminate material comprising several layers of fiber bonded together by a ceramic matrix. The un-bonded portion16is also made from a CMC material. The un-bonded portion16is appended to the bonded portion14to move relative to the bonded portion14in response to application of the load12. As a result, the compliant composite component10deforms in a controlled manner without fracture or damage to the compliant composite component10. In one example, the compliant composite component10may be a segment of a segmented blade track for a gas turbine engine, a turbine blade, or a turbine vein.

As shown, for example, inFIG. 1, the un-bonded portion16includes a first un-bonded section21, a second un-bonded section22, and a third un-bonded section23. The first un-bonded section21is coupled to the bonded portion14to move relative to the bonded portion14in response to application of the load12. The second un-bonded section22is coupled to the bonded portion14to move relative to the bonded portion14and the first un-bonded section21in response to application of the load12. The third un-bonded section23is coupled to the bonded portion14to move relative to the bonded portion14, the first un-bonded section21, and the second un-bonded section22in response to application of the load12. While three un-bonded sections21,22,23are shown, more or less un-bonded sections may be used in accordance with the present disclosure.

In one illustrative example, the third un-bonded section23is located between the bonded portion14and the second un-bonded section22. The second un-bonded section22is located between the third un-bonded section23and the first un-bonded section21.

The compliant composite component10has a load vs. deflection curve18including, in series, a first segment31, a second segment32, a third segment33, and a fourth segment34as shown, for example, inFIG. 2. The first segment31is provided by the first un-bonded section21and has a first slope. The second segment32is provided by the second un-bonded section22and has a second slope. The third segment33is provided by the third un-bonded section23and has a third slope. The fourth segment34is provided by the bonded portion14and has a fourth slope.

As shown, for example, inFIG. 1, the second slope is greater than the first slope. The third slope is greater than the fourth slope. The fourth slope is greater than the third slope.

Another embodiment of a compliant composite component110in accordance with the present disclosure is shown, for example, inFIG. 3undergoing application of an increasing load112. The compliant composite component110includes a bonded portion114and an un-bonded portion116as shown inFIG. 3. The bonded portion114is made from a Ceramic Matrix Composite (CMC) material. In one example, the CMC material is a laminate material comprising several layers of fiber bonded together by a ceramic matrix. The un-bonded portion116is also made from a CMC material. The un-bonded portion116is appended to the bonded portion114to move relative to the bonded portion114in response to application of the load112. As a result, the compliant composite component110deforms in a controlled manner without fracture or damage to the compliant composite component110.

As shown, for example, inFIG. 3, the un-bonded portion116includes a first lower un-bonded section121L, a second lower un-bonded section122L, and a third lower un-bonded section123L. The first lower un-bonded section121L is coupled to the bonded portion114to move relative to the bonded portion114in response to application of the load112. The second lower un-bonded section122L is coupled to the bonded portion114to move relative to the bonded portion114and the first lower un-bonded section121L in response to application of the load112. The third lower un-bonded section123L is coupled to the bonded portion114to move relative to the bonded portion114, the first lower un-bonded section121L, and the second lower un-bonded section122L in response to application of the load112. While three lower un-bonded sections121L,122L,123L are shown, more or less un-bonded sections may be used in accordance with the present disclosure.

The un-bonded portion116further includes a first upper un-bonded section121U, a second upper un-bonded section122U, and a third upper un-bonded section123U as shown inFIG. 3. The first upper un-bonded section121U is coupled to the bonded portion114to move relative to the bonded portion114in response to application of the load112. The second upper un-bonded section122U is coupled to the bonded portion114to move relative to the bonded portion114and the first upper un-bonded section122U in response to application of the load112. The third upper un-bonded section123U is coupled to the bonded portion114to move relative to the bonded portion114, the first upper un-bonded section121U, and the second upper un-bonded section122U in response to application of the load112.

The bonded portion114includes a first bonded section114A and a second bonded section1148. The second bonded section1146is located between the third lower and upper un-bonded sections123L,123U. The second upper un-bonded section122U is located between the third upper un-bonded section123U and the first upper un-bonded section121U. The second lower un-bonded section122L is located between the third lower un-bonded section123L and the first lower un-bonded section121L.

The compliant composite component110has a load vs. deflection curve118including, in series, a first segment131, a second segment132, a third segment133, and a fourth segment134as shown, for example, inFIG. 4. The first segment131is provided by the first upper and lower un-bonded sections121U,121L and has a first slope. The second segment132is provided by the upper and lower second un-bonded section122U,122L and has a second slope. The third segment133is provided by the upper and lower third un-bonded section123U,123L and has a third slope. The fourth segment134is provided by the bonded portion114and has a fourth slope.

In one illustrative example, the first slope is greater than the second slope. The third slope is greater than the second slope. The fourth slope is greater than the second and third slopes. The first slope is about equal to the fourth slope.

The compliant composite component110further includes a component mount120as shown inFIG. 3. The component mount120is coupled to the un-bonded portion116and configured to apply the load112which is a pre-loading of the un-bonded portion116as shown inFIG. 3. In another illustrative example, the load112includes a first force112A applied by the component mount120to the un-bonded portion116. The load112further includes a second force112B applied to the bonded portion114in a direction opposite the first force112A as shown inFIG. 5.

In still yet another illustrative example, a load212is applied to the compliant composite component110as shown inFIG. 7. The load212includes a first force212A applied to the un-bonded portion116in a first direction by the component mount120. The load212further includes a second force212B applied to the bonded portion114in the first direction. The load212yet includes a third force212C applied to the bonded portion114in a second direction opposite the first direction as shown inFIG. 7. In this example, the load212is the result of a impact to the compliant composite component110or a load reversal. As associated load vs. deflection curve218is shown inFIG. 8.

Another embodiment of a compliant composite component310in accordance with the present disclosure is shown, for example, inFIG. 9undergoing application of an increasing load312. The compliant composite component310includes a bonded portion314and an un-bonded portion316as shown inFIG. 9. The bonded portion314is made from a Ceramic Matrix Composite (CMC) material. In one example, the CMC material is a laminate material comprising several layers of fiber bonded together by a ceramic matrix. The un-bonded portion316is also made from a CMC material. The un-bonded portion316is appended to the bonded portion314to move relative to the bonded portion314in response to application of the load312. As a result, the compliant composite component310deforms in a controlled manner without fracture or damage to the compliant composite component110.

The bonded portion314includes a first bonded section314A and a second bonded section314B. The second bonded section314B is appended to the first bonded section314A to extend away from the first bonded section314A as shown inFIG. 9.

The un-bonded portion316includes a first un-bonded section321, a second un-bonded section322, and a third un-bonded section323as shown inFIG. 9. The first un-bonded section321is appended to the second bonded section314B to move relative to the second bonded section314B in response to application of the load312. The second un-bonded section322is appended to the second bonded section314B to move relative to the second bonded section314B and the first un-bonded section321in response to application of the load312. The third un-bonded section323is appended to the second bonded section314B to move relative to the second bonded section314B, the first un-bonded section321, and the second un-bonded section322in response to application of the load312.

The third un-bonded section323is coupled to the first bonded section314A to translate relative to the first bonded section314A. The third un-bonded section323is appended to the second bonded section314B to pivot relative to the second bonded section314B, the second un-bonded section322, and the first un-bonded section321as shown inFIG. 9. The second un-bonded section322is coupled to the third un-bonded section323to translate relative to the third un-bonded section323. The second un-bonded section322is appended to the second bonded section314B to pivot relative to the second bonded section314B, the third un-bonded section323, and the first un-bonded section321.

As shown, for example, inFIG. 9, the first un-bonded section321is coupled to the second un-bonded section322to translate relative to the second un-bonded section322, the third un-bonded section323, and second bonded section314B. The first un-bonded section321is appended to the second bonded section314B to pivot relative to the second bonded section314B, the second un-bonded section322, and the third un-bonded section323.

The third un-bonded section323is located between the first bonded section314A and the second un-bonded section322. The second un-bonded section322is located between the third un-bonded section323and the first un-bonded section321.

The compliant composite component310has a load vs. deflection curve318as shown, for example, inFIG. 10. The load vs. deflection curve318includes, in series, a first segment331, a second segment332, a third segment333, and a fourth segment334. The first segment331is provided by the first un-bonded section321and has a first slope. The second segment332is provided by the second un-bonded section322and has a second slope. The third segment is provided by the third un-bonded section323and having a third slope. The fourth segment334is provided by the bonded portion314and has a fourth slope. The second slope is greater than the first slope. The third slop is greater than the fourth slope. The fourth slope is greater than the third slope.

In one illustrative example, the third un-bonded section323is located between the first bonded section314A and the second un-bonded section322as shown inFIG. 9. The second un-bonded section322is located between the third un-bonded section323and the first un-bonded section321.

Another embodiment of a compliant composite component410in accordance with the present disclosure is shown, for example, inFIG. 11undergoing application of an increasing load412. The compliant composite component410includes a bonded portion414, an un-bonded portion416, and component mount420as shown inFIG. 11. In one illustrative example, the component mount420is a hinge as shown inFIG. 11. The bonded portion414is made from a Ceramic Matrix Composite (CMC) material. In one example, the CMC material is a laminate material comprising several layers of fiber bonded together by a ceramic matrix. The un-bonded portion416is also made from a CMC material. The un-bonded portion416is appended to the bonded portion414to move relative to the bonded portion414in response to application of the load412. As a result, the compliant composite component410deforms in a controlled manner without fracture or damage to the compliant composite component410.

The compliant composite component410has a load vs. deflection curve418as shown, for example, inFIG. 12. The load vs. deflection curve418includes, in series, a first segment431and a second segment432. The first segment431is provided by the un-bonded portion416and has a first slope. The second segment432is provided by the bonded portion414and has a second slope. The second slope is greater than the first slope.

A method of fabricating a Ceramic Matrix Composite (CMC) component increases local compliance to improve load transfer from the CMC component to adjacent components. CMC components are relatively stiff (40 MSI/1280 GPa typical young's modulus) and metal components have vastly different Coefficients of Thermal Expansion (CTE). As a result, introducing load uniformity to the CMC component may be difficult. In addition, manufacturing tolerances complicate stresses at load interfaces between CMC components and metal components. While metal components may yield or creep to accommodate these loads, composite components may crack and be subject to subsequent degradation as a result. While un-bonded or de-bonded sections of a composite component are typically considered as defects, the un-bonded sections of the composite components of the present disclosure are created intentionally to exploit the additional compliance.

The compliance of the attachment region may be designed for the desired compliance characteristics. This includes the potential to create progressive or variable compliance designs. In most instances the compliant areas will be designed to contact other layers as load is applied. By limiting deflection of the compliant material, stresses may be controlled to achieve the desired life (fatigue, etc.) characteristics.

A method of fabricating a compliant composite component in accordance with the present disclosure includes multiple operations. The compliant composite component may be fabricated during manufacture of the base component or through post-manufacture machining. The compliant composite component may be fabricated during composite process.

One example of a method of fabricating a compliant composite component is discussed below. The method comprises the operations of inserting a material that is oxidized, etched, dissolved, vaporized, sublimated, or otherwise removed after some stage of composite processing to leave a void. For example, graphoil (a carbon sheet made from flake graphite) may be inserted temporarily then removed mechanically or by oxidation. The method further includes applying a material (e.g., boron nitride, carbon, molybdenum disulfide) that impairs the bond between lamina or sections of the material.

The method further includes using multi-layered textile pre-forms. The multi-layered pre-forms may be locally woven to allow layer separation or cut after textile operations are complete to permit manipulation. Multi-layer textiles may be created with very localized connections that are broken after processing or broken during application of the load as part of the design. These joining points will hold the textile open during processing.

The method further includes delaminating forcibly the composite. The composite may be delaminated through mechanical means (wedging or applying interlaminar tension) or thermal shock means to produce the desired compliance.

The method further includes inserting a textile that does not bond well with the primary material. Thermal mismatch of fibers and limited contact area can both result in poorly bonded or unbounded areas.

The method further includes omitting material locally to create an intentional void in the material. As an example, an area could be removed from several layers of the textile or simply not woven into a three-dimensional textile.

The method further includes inserting a material that survives processing to some stage. However, the thermal expansion difference between this material and the composite may result in delamination during cool down or thermal cycling

In a laminated structure, such as shown inFIG. 1, the design should attempt to limit interlaminar stresses like tension and shear. Interlaminar compression is preferred to minimize the risk of delamination.

In some instances where the contact between surfaces varies in angle, it may be desirable to incorporate a pivot point or other means to maintain relatively constant contact area to minimize surface point stresses. It may be preferred in some instances to have matching compliance and geometry on the contact surface so that both materials deflect and maintain constant contact. Even when matched compliance is not possible, similar compliance may be provided.

The compliant composite component of the present disclosure may be applied to high stiffness organic and metal matrix composites. The compliant composite component maximizes uniformity of load transfer through a range of operating conditions leading to maximize performance and component life.

The compliant composite component provides substantially uniform contact between components. Uniform contact is maintained or minimal gaps occur with attachment of the compliant composite component to seal or limit gas or liquid flow.

The compliant composite component provides for pre-loading upon assembly so that a component is always under load. As a result, wear and vibration may be minimized.

The compliant composite component may allow for significantly greater deflections that may allow a component to rotate or translate significantly. Such movement may be useful when an abnormal overstress occurs to an adjacent component that creates contact with the CMC component which may move to minimize damage to both components. If an impact occurs (for instance FaD to a vane), the CMC component may dissipate some of the energy through deflection and minimize component damage. Flexing of the compliant composite component may provide for improved performance.

The compliant composite component of the present disclose demonstrates better load transfer and lower stress states which provides less damage during overloads and demonstrate more consistent part fit and performance. The compliant composite component also provides for improved sealing. As a result, the compliant composite component may have longer component life, reduced component weight, or lower acquisition cost as a result of reduced need for tight tolerances and consequently higher production yield.