公开(公告)号：US20230192564A1

公开(公告)日：2023-06-22

申请号：US17559277

申请日：2021-12-22

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Pathikumar Sellappan ,  Nesredin Kedir ,  Stephen Isaiah Harris

IPC: C04B37/00

CPC classification number: C04B37/003 ,  C04B2237/09 ,  C04B2237/38 ,  C04B2237/60 ,  C04B2237/083 ,  C04B2237/84

Abstract: In some examples, a method including forming a layer of a slurry composition between a first ceramic or CMC part and a second ceramic or CMC part. The slurry composition includes a carrier material; and a plurality of solid particles in the carrier material. The plurality of solid particles includes first silicon carbide (SiC) particles defining a first average particle size, second SiC particles defining a second average particles size that is less than the first average particles size, and reactive additive particles. The method includes heating the layer of slurry composition to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles, wherein the fused layer of the slurry composition forms a joint layer that joins the first ceramic or CMC part to the second ceramic or CMC part.

公开(公告)号：US11667580B2

公开(公告)日：2023-06-06

申请号：US17012977

申请日：2020-09-04

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Pathikumar Sellappan ,  Sungbo Shim ,  Kevin Mark Lukhard

IPC: C04B35/80 ,  F01D25/08 ,  C04B35/628 ,  C04B35/657 ,  C04B41/00 ,  C04B41/50 ,  C04B41/87 ,  B28B11/04

CPC classification number: C04B35/80 ,  B28B11/041 ,  C04B35/62863 ,  C04B35/62873 ,  C04B35/657 ,  C04B41/009 ,  C04B41/5059 ,  C04B41/87 ,  F01D25/08 ,  C04B2235/3826 ,  C04B2235/48 ,  C04B2235/5252 ,  C04B2235/616 ,  F05D2220/32 ,  F05D2230/20 ,  F05D2230/90

Abstract: A method is provided in which a resin coating is applied to a surface of a preform. The resin coating includes a carbonaceous resin and a particulate. The preform is added to a tooling. The preform, which is positioned in the tooling, is cured. The tooling is removed. The resin coating on the surface of the preform is pyrolyzed to form a resin carbon-char layer on the surface of the preform. The preform and the resin carbon-char layer are infiltrated with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide. During the infiltration, the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform.

公开(公告)号：US11186525B2

公开(公告)日：2021-11-30

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 ,  C04B41/50 ,  C04B41/45 ,  C04B35/83 ,  C04B35/645

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：US12180122B2

公开(公告)日：2024-12-31

申请号：US17559277

申请日：2021-12-22

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Pathikumar Sellappan ,  Nesredin Kedir ,  Stephen Isaiah Harris

IPC: C04B37/00

Abstract: In some examples, a method including forming a layer of a slurry composition between a first ceramic or CMC part and a second ceramic or CMC part. The slurry composition includes a carrier material; and a plurality of solid particles in the carrier material. The plurality of solid particles includes first silicon carbide (SiC) particles defining a first average particle size, second SiC particles defining a second average particles size that is less than the first average particles size, and reactive additive particles. The method includes heating the layer of slurry composition to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles, wherein the fused layer of the slurry composition forms a joint layer that joins the first ceramic or CMC part to the second ceramic or CMC part.

公开(公告)号：US20240025812A1

公开(公告)日：2024-01-25

申请号：US17871401

申请日：2022-07-22

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Jeffrey Crutchfield ,  Pathikumar Sellappan ,  Chris Downie ,  Christopher Mara ,  Sungbo Shim

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

CPC classification number: C04B35/80 ,  C04B35/657 ,  C04B35/62894 ,  C04B35/62892 ,  C04B35/62884 ,  C04B35/62897 ,  C04B2235/5252 ,  C04B2235/616 ,  C04B2235/612

Abstract: A method to produce a ceramic matrix composite part, wherein the method comprises providing a ceramic fiber preform. Wherein the ceramic fiber preform includes a three-dimensional framework of a plurality of ceramic fibers. The method comprising, prior to melt infiltration, adding a layer of machinable stock to a target area of the ceramic fiber preform, melt infiltrating the ceramic fiber preform, forming the ceramic matrix composite part by cooling the melt infiltrated ceramic fiber preform, and machining the part in the target area where the machinable stock is located.

公开(公告)号：US20210114942A1

公开(公告)日：2021-04-22

申请号：US17070148

申请日：2020-10-14

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Sungbo Shim ,  Pathikumar Sellappan

IPC: C04B37/00 ,  C04B41/00 ,  C04B41/50 ,  C04B41/45 ,  C04B41/87

Abstract: A method is provided in which a first tape is applied to an outer surface of a ceramic matrix composite (CMC). A second tape is applied to the first tape. The second tape is heated to at least a melting temperature of the second tape. During heating, the first tape is infiltrated with a molten material from the second tape, which forms a surface layer on the CMC

公开(公告)号：US20210070663A1

公开(公告)日：2021-03-11

申请号：US17012952

申请日：2020-09-04

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Pathikumar Sellappan ,  Sungbo Shim

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

Abstract: A system of infiltration for producing a ceramic matrix composite (CMC) is provided in which a slurry is applied to an outer surface of a porous preform. The porous preform includes a framework of ceramic fibers. The slurry may include a solvent and a particulate. The porous preform may be infiltrated with the slurry. The particulate in the slurry may include a plurality of coarse particles and a plurality of fine particles. The coarse particles may have a d50 factor of 10-20 microns. The fine particles may have a d50 factor of 0.5-3 microns. A ratio of coarse particles to fine particles in the slurry may be between 1.5:1 and 4:1, inclusively.

公开(公告)号：US20210024426A1

公开(公告)日：2021-01-28

申请号：US16922609

申请日：2020-07-07

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Sungbo Shim ,  Robert Shinavski ,  Pathikumar Sellappan

IPC: C04B35/78 ,  C04B41/45 ,  C04B41/50

Abstract: A method of forming a barrier layer on a ceramic matrix composite (CMC) is described. The method includes forming a particulate surface layer comprising silicon particles on an outer surface of a fiber preform. The particulate surface layer is nitrided to convert the silicon particles to silicon nitride particles. After the nitriding, the fiber preform and the particulate surface layer are infiltrated with a molten material comprising silicon. Following infiltration, the molten material is cooled, thereby forming a ceramic matrix composite with a barrier layer thereon, where the barrier layer comprises silicon nitride and less than 5 vol. % free silicon. The barrier layer may also include silicon carbide and/or one or more refractory metal silicides.