Patent ID: 7854969

Claim:
A method of manufacturing an integral composite structural material for use in turbine engine components comprising the steps of: (a) providing an open metal structure having inner surfaces of metal defining a plurality of apertures that extend entirely through the metal structure such that the apertures have continuous inner surfaces and at least one external side, said metal structure being selected from the group consisting of aluminum, high strength low alloy steel, stainless steel, carbon steel, nickel-based superalloys, iron-based superalloys, and cobalt-based superalloys, said apertures having a geometry such that no dimension of said apertures is greater than about ¾ inch, wherein the total metal volume percent of the integral composite structural material, exclusive of ceramic matrix composite precursor material, is in the range of about 10% to about 90%; (b) providing a prepreg ceramic paper of ceramic matrix composite precursor material, wherein the ceramic matrix composite precursor material further includes ceramic fibers and ceramic matrix material, wherein the ceramic fibers are selected from the group consisting of alumina fibers, silica fibers, boric oxide fibers, silicon carbide fibers, glass fibers, and combinations thereof, and wherein the ceramic matrix material is selected from the group consisting of zirconia, hafnia, alumina silicate, yttria, calcia aluminate, clay and combinations thereof; (c) applying the prepreg ceramic paper of ceramic matrix composite precursor material to the open metal structure by pressing the prepreg ceramic paper onto at least one external side of the open metal structure and into the plurality of apertures of the open metal structure; (d) laminating the prepreg ceramic paper to the open metal structure so that the ceramic matrix composite precursor material is disposed on and within the apertures and wherein the ceramic matrix composite precursor material occupies and covers the inner surfaces of the open metal structure and the laminated ceramic matrix composite precursor material and open metal structure form an integrated composite structural precursor material; and (e) sintering the laminated ceramic matrix composite precursor material in an oxidative environment at a temperature in the range of about 600° C. to about 1100° C. to transform the ceramic matrix composite precursor material into a ceramic matrix composite material adapted for use in turbine engine components, said ceramic matrix composite material being chemically bonded to the at least one external side and said inner surfaces of the open metal structure, which transforms the integral composite structural precursor material into the integral structural composite material adapted for use in turbine engine components.