公开(公告)号：US10941079B2

公开(公告)日：2021-03-09

申请号：US15261394

申请日：2016-09-09

Applicant: Rolls-Royce High Temperature Composites, Inc. ,  Rolls-Royce Corporation

Inventor： Sungbo Shim ,  Kang N. Lee ,  Stephen Isaiah Harris ,  Andrew Joseph Lazur

IPC: C04B37/00 ,  C23C28/00 ,  F01D5/28 ,  C04B41/89 ,  C23C20/04 ,  C04B41/00 ,  C04B41/85 ,  C04B41/45 ,  C04B41/50 ,  C04B41/52

Abstract: In some examples, a method may include depositing, from a slurry comprising particles including silicon metal, a bond coat precursor layer including the particles comprising silicon metal directly on a ceramic matrix composite substrate. The method also may include locally heating the bond coat precursor layer to form a bond coat comprising silicon metal. Additionally, the method may include forming a protective coating on the bond coat. In some examples, an article may include a ceramic matrix composite substrate, a bond coat directly on the substrate, and a protective coating on the bond coat. The bond coat may include silicon metal and a metal comprising at least one of Zr, Y, Yb, Hf, Ti, Al, Cr, Mo, Nb, Ta, or a rare earth metal.

公开(公告)号：US10907493B2

公开(公告)日：2021-02-02

申请号：US16189648

申请日：2018-11-13

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies Inc. ,  Rolls-Royce High Temperature Composites Inc.

Inventor： Daniel Kent Vetters ,  David J. Thomas ,  Douglas David Dierksmeier ,  Jun Shi ,  Todd Engel

IPC: F01D11/12 ,  F01D25/24 ,  F01D9/02

Abstract: A segmented turbine shroud for radially encasing a rotatable turbine in a gas turbine engine comprising a carrier, a ceramic matrix composite (CMC) seal segment, and an elongated pin. The carrier defines a pin-receiving carrier bore and the CMC seal segment defines a pin-receiving seal segment bore. The elongated pin extends through the carrier bore and the seal segment bore. The pin-receiving carrier bore includes a cantilevered member such that the carrier bore has a length sufficient to effect radial flexion between the carrier bore and the pin received within the carrier bore during operation of the turbine.

公开(公告)号：US20210009479A1

公开(公告)日：2021-01-14

申请号：US16508562

申请日：2019-07-11

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Thomas E. Krause ,  Robert Shinavski ,  Kevin Mark Lukhard

IPC: C04B41/50 ,  C04B35/80 ,  C04B41/45

Abstract: A method for infiltrating a porous preform for a gas turbine engine is provided, which comprises providing a chamber for infiltrating a porous preform. The porous preform is positioned within a slurry confinement fixture within the chamber. A vacuum is created in the chamber. A solvent is added to the slurry confinement fixture until a pressure in the chamber is substantially equal to an equilibrium partial pressure of the solvent. A slurry is added to the slurry confinement fixture. The slurry includes the solvent and a particulate. The pressure in the chamber is increased, and the slurry is urged into the porous preform.

公开(公告)号：US20210003024A1

公开(公告)日：2021-01-07

申请号：US16845820

申请日：2020-04-10

Applicant: Rolls-Royce North American Technologies Inc. ,  Rolls-Royce Corporation ,  Rolls-Royce High Temperature Composites Inc.

Inventor： Daniel K. Vetters ,  David J. Thomas ,  Ted Freeman ,  Joseph Lamusga ,  Rick Uskert ,  Douglas D. Dierksmeier ,  Jun Shi ,  Todd Engel ,  Matt Brandt

IPC: F01D11/02 ,  F01D9/04 ,  F01D25/24

Abstract: A ceramic matrix composite (CMC) seal segment for use in a segmented turbine shroud for radially encasing a turbine in a gas turbine engine. The CMC seal segment comprises an arcuate flange having a surface facing the turbine and a portion defining a bore for receiving an elongated pin, with the bore having a length that is at least 70% of the length of the elongated pin received therein. The CMC seal segment is carried by the carrier by at least one of the elongated pins being received within the bore. The CMC seal segment portion defining a pin-receiving bore is radially spaced from the arcuate flange by a spacing flange extending radially outward from the arcuate flange.

公开(公告)号：US10822280B2

公开(公告)日：2020-11-03

申请号：US16116173

申请日：2018-08-29

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Stephen Harris ,  David Smolenski

IPC: C04B35/80 ,  C04B35/628 ,  C04B35/634 ,  C04B35/638 ,  C04B35/657 ,  C04B37/00 ,  B29C70/00 ,  B29C48/00 ,  B29C48/08 ,  B29B11/00 ,  B32B37/15 ,  B32B38/00 ,  C08J5/12 ,  B32B5/02 ,  B32B9/00 ,  C08J5/24 ,  B32B37/20

Abstract: A method of making a fiber preform for ceramic matrix composite (CMC) fabrication comprises laminating an arrangement of fibers between polymer sheets comprising an organic polymer, which may function as a fugitive binder during fabrication, to form a flexible prepreg sheet. A plurality of the flexible prepreg sheets are laid up in a predetermined geometry to form a stack, and the stack is heated to soften the organic polymer and bond together the flexible prepreg sheets into a bonded prepreg structure. Upon cooling of the bonded prepreg structure, a rigid preform is formed. The rigid preform is heated at a sufficient temperature to pyrolyze the organic polymer. Thus, a porous preform that may undergo further processing into a CMC is formed.

公开(公告)号：US20200277694A1

公开(公告)日：2020-09-03

申请号：US16804437

申请日：2020-02-28

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies, Inc. ,  Rolls-Royce High Temperature Composites, Inc.

Inventor： Ann Bolcavage ,  Bradley Wing ,  Matthew R. Gold

IPC: C23C4/18 ,  C23C4/02 ,  C23C4/134

Abstract: In one example, a method for forming an environmental barrier coating (EBC) on a substrate. The method may include depositing an environmental barrier coating (EBC) on a substrate via a thermal spray apparatus to form an as-deposited EBC; heat treating the as-deposited EBC at or above a first temperature for first period of time following the deposition of the as-deposited EBC on the substrate; and cooling the as-deposited EBC to a second temperature following the heat treatment at a controlled rate over a second period of time to form a heat-treated EBC on the substrate. The first temperature, the first period of time, the controlled rate, and the second period of time may be selected to increase a weight percent of crystalline phase in the heat-treated EBC compared to the as-deposited EBC.

公开(公告)号：US10745803B2

公开(公告)日：2020-08-18

申请号：US16003615

申请日：2018-06-08

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Richard W. Kidd ,  Robert Shinavski

IPC: C23C16/34 ,  C04B35/628 ,  C04B35/80 ,  C04B35/565 ,  C23C16/30 ,  D06M11/58 ,  D06M11/80 ,  F01D25/00 ,  D06M101/16

Abstract: A method of forming a moisture-tolerant coating on a silicon carbide fiber includes exposing a silicon carbide fiber to a gaseous N precursor comprising nitrogen at an elevated temperature, thereby introducing nitrogen into a surface region of the silicon carbide fiber, and exposing the silicon carbide fiber to a gaseous B precursor comprising boron at an elevated temperature, thereby introducing boron into the surface region of the silicon carbide fiber. Silicon-doped boron nitride is formed at the surface region of the silicon carbide fiber without exposing the silicon carbide fiber to a gaseous Si precursor comprising Si. Thus, a moisture-tolerant coating comprising the silicon-doped boron nitride is grown in-situ on the silicon carbide fiber.

公开(公告)号：US10704407B2

公开(公告)日：2020-07-07

申请号：US15950698

申请日：2018-04-11

Applicant: Rolls-Royce High Temperature Composites Inc. ,  Rolls-Royce North American Technologies Inc.

Inventor： Chris Barrett ,  Joseph P. Lamusga ,  Ted J. Freeman

IPC: F01D11/08 ,  F01D25/24

Abstract: A turbine shroud adapted for use in a gas turbine engine includes an attachment feature and a body. The attachment feature and the body are constructed of ceramic matrix composite materials. In an illustrative embodiment, the ceramic matrix composite materials form a blade track segment.

公开(公告)号：US10689299B2

公开(公告)日：2020-06-23

申请号：US16058712

申请日：2018-08-08

Applicant: Rolls-Royce Corporation ,  Rolls-Royce High Temperature Composites, Inc.

Inventor： Anthony Martin Goetz ,  Robert J. Shinavski ,  Stephen Isaiah Harris ,  Sean E. Landwehr

IPC: C04B41/85 ,  C04B35/80 ,  C04B41/45 ,  C04B41/87 ,  C04B41/53 ,  C04B41/52 ,  C04B41/50 ,  C04B35/565 ,  C04B35/573 ,  C04B35/626 ,  C04B35/628 ,  C04B35/634 ,  C04B35/636 ,  C04B35/622 ,  C04B35/624 ,  C04B35/65 ,  C04B35/657

Abstract: A method of forming a composite article includes impregnating an inorganic fiber preform with a slurry composition. The slurry composition includes a particulate, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to immobilize the particulate and yield a gelled article, and substantially all solvent is removed from the gelled article to form a green composite article. The green composite article is then infiltrated with a molten infiltrant to form the composite article.

公开(公告)号：US20200123069A1

公开(公告)日：2020-04-23

申请号：US16163754

申请日：2018-10-18

Applicant: Rolls-Royce Corporation ,  Rolls-Royce High Temperature Composites, Inc.

Inventor： Sungbo Shim ,  Jun Shi

IPC: C04B37/02 ,  B28B1/52 ,  C04B41/00 ,  C04B41/53 ,  C04B41/91 ,  C04B35/80 ,  C04B35/657 ,  C04B35/628 ,  F01D9/02

Abstract: A method of processing a ceramic matrix composite (CMC) component includes extracting silicon from a surface region of the CMC component such that free silicon is present in the surface region at a reduced amount of about 5 vol. % or less. The extraction comprises contacting the surface region with a wicking medium comprising an element reactive with silicon. The extraction is carried out at an elevated temperature prior to assembling the CMC component with a metal component.