公开(公告)号：US11162377B2

公开(公告)日：2021-11-02

申请号：US16428319

申请日：2019-05-31

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

Inventor： Robert J. Shinavski ,  Thomas Tran ,  Kevin Lukhard ,  Ted J. Freeman ,  Steffan Brown

IPC: F01D9/04 ,  F01D5/28 ,  F01D25/00

Abstract: A turbine vane comprising ceramic matrix composite materials. The turbine vane includes an vane support core, an airfoil, and a pair of end walls that are spaced apart from one another to define a gas path. The turbine vane is formed from a plurality of ceramic plies or preforms that are infiltrated with ceramic matrix material to form a one-piece ceramic matrix composite turbine vane.

公开(公告)号：US11149581B2

公开(公告)日：2021-10-19

申请号：US16692617

申请日：2019-11-22

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

Inventor： Michael J. Whittle ,  Anthony G. Razzell ,  Stephen I. Harris

IPC: F01D21/00 ,  F02C7/00

Abstract: A component for use in a gas turbine engine includes a component body, and a damage-indicative coating. The damage-indicative coating is configured to change from an intact state in which the damage-indicative coating has a first appearance to a damaged state in which the damage-indicative coating has a second appearance.

公开(公告)号：US20210188723A1

公开(公告)日：2021-06-24

申请号：US17119345

申请日：2020-12-11

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

Inventor： Robert Alexander Sean Golden ,  Sungbo Shim ,  Li Li ,  Taylor K. Blair

IPC: C04B41/52 ,  C04B35/80 ,  C04B41/00 ,  C04B41/45 ,  C04B41/50 ,  C04B41/87 ,  C04B41/89

Abstract: The disclosure describes braze tape coatings and technique to form articles with differing physical properties in different layers or regions of the article. An example method includes forming a braze tape defining at least one layer that includes a first segment and a second segment. A portion of the second segment in the plane is adjacent to a portion of the first segment in a plane of the layer. The method also includes positioning the braze tape on a surface of a substrate, the plane of the layer of the braze tape being parallel to the surface of the substrate. The method also includes heating the braze tape to melt a constituent of at least one of the first coating material and the second coating material to form a densified coating on the surface of the substrate.

公开(公告)号：US11021779B2

公开(公告)日：2021-06-01

申请号：US15963212

申请日：2018-04-26

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

Inventor： Chris Barrett ,  Steffan Brown

IPC: C22C47/08 ,  C22C47/06 ,  B32B5/26 ,  D03D11/00 ,  B32B1/00 ,  B32B5/02 ,  C04B35/622 ,  C23C16/04 ,  D03D25/00 ,  C04B35/80 ,  B22F5/04 ,  B22F5/00 ,  C04B41/51 ,  D03D15/68

Abstract: A ceramic matrix composite (CMC) is formed using a three-dimensional (3-D) woven preform by removing the set of sacrificial fibers from the 3-D woven preform and allowing a metal or metal alloy infiltrate the 3-D woven preform. The 3-D woven preform is formed by a method that includes providing a woven layer comprising a first set of ceramic fibers oriented in a first (x) direction woven with a second set of ceramic fibers oriented in a second (y) direction; stacking a plurality of woven layers on top of each other, said woven layers providing a two-dimensional (2-D) preform; weaving a set of sacrificial fibers in a third (z) direction with the 2-D preform, said weaving providing the 3-D woven preform; and shaping the 3-D woven preform into a predetermined shape.

公开(公告)号：US20210147302A1

公开(公告)日：2021-05-20

申请号：US17066814

申请日：2020-10-09

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Camila S. Bortoluzzi ,  Stephen J. Richards

IPC: C04B35/80 ,  C04B35/628 ,  C04B35/657

Abstract: A method of producing a CMC having a smooth surface includes forming a fiber preform; rigidizing the preform with an interphase coating; infiltrating a ceramic slurry into the preform to form a green body; conducting secondary operations on the green body; applying a slurry-based layer onto a portion of the green body; and infiltrating the green body with a molten silicon or silicon alloy, such that the CMC exhibits a smooth surface. The application of the slurry-based surface layer onto the green body includes placing the green body into a tool fixture having upper and lower components, such that a gap is present between the green body and at least one of the upper and lower components; and delivering a surface layer slurry into at least one gap, such that the surface layer slurry forms the slurry-based layer on at least a portion of the green body.

公开(公告)号：US20210069931A1

公开(公告)日：2021-03-11

申请号：US17015840

申请日：2020-09-09

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Pathikumar Sellappan ,  Sungbo Shim

IPC: B28B11/24 ,  C04B35/64

Abstract: Methods of reducing dry crack formation in ceramic matrix composite green bodies are provided. Some of the methods expose the green body to a gaseous atmosphere at a relatively high humidity for a first period, and then slowly lower the humidity over a second period, where the gaseous atmosphere is at room temperature for both periods. Other methods start the gaseous atmosphere at room temperature and then raise the temperature to a higher temperature while the humidity is relatively high, and hold that temperature even as the humidity is lowered in the second period.

公开(公告)号：US20210032172A1

公开(公告)日：2021-02-04

申请号：US16524397

申请日：2019-07-29

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Sungbo Shim ,  Pathikumar Sellappan

IPC: C04B41/87 ,  C04B35/83 ,  C04B41/45 ,  C04B41/50

Abstract: A method to produce a protective surface layer having a predetermined topography on a ceramic matrix composite is described. The method includes applying a slurry layer to a surface of a fiber preform, and drying the slurry layer to form a particulate layer. A surface of the particulate layer is machined to improve surface smoothness and to form a machined surface. A ceramic tape is attached to the machined surface, and a tool comprising one or more features to be imprinted is placed on the ceramic tape, thereby forming a compression assembly. Heat and pressure are applied to the compression assembly to consolidate and bond the ceramic tape to the machined surface, while the one or more features of the tool are imprinted. Thus, a protective surface layer having a predetermined topography is formed.

公开(公告)号：US10787917B2

公开(公告)日：2020-09-29

申请号：US15971356

申请日：2018-05-04

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

Inventor： Ted J. Freeman ,  Christopher Barrett

IPC: F01D5/30

Abstract: A multi-piece disk for use in a turbine of a gas turbine engine. The multi-piece disk includes a fore disk segment and an aft disk segment coupled with the fore disk segment for movement with the fore disk segment. The fore disk segment and the aft disk segment are formed to define slots that extend through the disk segments and are configured to receive turbine blades therein.

公开(公告)号：US10731252B2

公开(公告)日：2020-08-04

申请号：US15989697

申请日：2018-05-25

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Stephen Harris

IPC: C23C16/455 ,  C04B41/85 ,  C04B41/87 ,  C04B41/45 ,  C23C16/32 ,  C23C16/34 ,  C23C16/26

Abstract: An apparatus for coating specimens includes a reaction chamber and a plurality of reaction modules in the reaction chamber for containing specimens to be coated, where each reaction module includes a module inlet and a module outlet. A plurality of conduits are configured to be in fluid communication with at least one gas source external to the reaction chamber, and each of the conduits terminates in one of the reaction modules for delivery of gaseous reagents to the specimens to be coated. The module outlets are in fluid communication with the reaction chamber for expulsion of gaseous reaction products from the reaction modules.

公开(公告)号：US20190323112A1

公开(公告)日：2019-10-24

申请号：US16388087

申请日：2019-04-18

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

Inventor： Sungbo Shim ,  Li Li

IPC: C23C4/10 ,  C23C4/134 ,  C04B35/622 ,  C04B35/565 ,  C04B35/587 ,  C04B41/50 ,  C04B41/87 ,  C04B41/00 ,  C04B41/45

Abstract: A composite bond coat may include a matrix and a reinforcing component. The matrix may be formed from silicon-based particles, and the reinforcing component includes silicon-based ceramic particles. The composite bond coat may be formed by introducing a precursor composition into a plume generated by a thermal spray gun to generate a thermal spray stream. The thermal spray stream may be directed at a major surface defined by a substrate of the component to form the composite bond coat. The precursor composition includes the matrix component and the reinforcing component.