公开(公告)号：US20170313627A1

公开(公告)日：2017-11-02

申请号：US15499960

申请日：2017-04-28

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Sungbo Shim ,  Robert Shinavski

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

Abstract: The disclosure describes techniques for infiltrating a porous preform with a slurry to form an infiltrated-preform, where the slurry includes a plurality of solid particles, where the plurality of solid particles include a plurality of fine ceramic particles defining an average fine particle diameter, a plurality of coarse ceramic particles defining an average coarse particle diameter, and a plurality of diamond particles, where the average fine particle diameter is less than the average coarse particle diameter, and infiltrating the infiltrated-preform with a molten metal infiltrant to form a ceramic matrix composite (CMC) article.

公开(公告)号：US11117838B2

公开(公告)日：2021-09-14

申请号：US15987269

申请日：2018-05-23

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Wayne Steffier ,  Michael Jacquinto ,  Stephen Harris ,  Robert Shinavski ,  Todd Engel

IPC: C04B35/80 ,  C04B35/634 ,  C04B35/638 ,  C04B35/657 ,  C04B35/628

Abstract: A method of making a fiber preform for ceramic matrix composite (CMC) fabrication that utilizes a fugitive binder and a machining step is described. The method includes, according to one embodiment, laying up a plurality of plies to form a stack, where each ply comprises an arrangement of fibers. The stack is infiltrated with a polymer at an elevated temperature to form an infiltrated stack that is cooled to form a rigid preform. The rigid fiber preform is machined to have a predetermined shape, such that a machined fiber preform is formed. A composite assembly including the machined fiber preform is formed and then the composite assembly is heated at a sufficient temperature to pyrolyze the polymer. Thus, a porous preform of a predetermined geometry is formed for further processing into a CMC.

公开(公告)号：US10774010B2

公开(公告)日：2020-09-15

申请号：US15499946

申请日：2017-04-28

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Sungbo Shim ,  Andrew Joseph Lazur ,  Robert Shinavski

IPC: C04B41/00 ,  C04B41/89 ,  C04B41/52 ,  C04B35/80 ,  F01D5/28 ,  B05D7/24 ,  B05D3/00 ,  B05D7/22

Abstract: Techniques for infiltrating a CMC substrate may include infiltrating the CMC substrate with a first slurry to at least partially fill at least some inner spaces of the CMC substrate, where the first slurry includes first solid particles, drying the first slurry to form an infiltrated CMC including the first solid particles, depositing a second slurry including a carrier material and second solid particles on a surface of the infiltrated CMC, where the second solid particles include a plurality of fine ceramic particles, a plurality of coarse ceramic particles, and a plurality of diamond particles, drying the second slurry to form an article having an outer surface layer including the second solid particles on the infiltrated CMC, and infiltrating the article with a molten infiltrant to form a composite article.

公开(公告)号：US10071936B2

公开(公告)日：2018-09-11

申请号：US15460990

申请日：2017-03-16

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

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

IPC: C04B35/80 ,  C04B35/626 ,  C04B35/622 ,  C04B35/624 ,  C04B35/65 ,  C04B35/657

CPC classification number: C04B35/806 ,  C04B35/565 ,  C04B35/573 ,  C04B35/62281 ,  C04B35/624 ,  C04B35/6261 ,  C04B35/6263 ,  C04B35/6264 ,  C04B35/62857 ,  C04B35/6286 ,  C04B35/62863 ,  C04B35/62865 ,  C04B35/62868 ,  C04B35/62873 ,  C04B35/634 ,  C04B35/636 ,  C04B35/6365 ,  C04B35/65 ,  C04B35/657 ,  C04B41/4584 ,  C04B41/5059 ,  C04B41/5096 ,  C04B41/52 ,  C04B41/53 ,  C04B41/85 ,  C04B41/87 ,  C04B2235/3826 ,  C04B2235/428 ,  C04B2235/48 ,  C04B2235/5224 ,  C04B2235/5228 ,  C04B2235/5232 ,  C04B2235/5236 ,  C04B2235/524 ,  C04B2235/5244 ,  C04B2235/5248 ,  C04B2235/5436 ,  C04B2235/5481 ,  C04B2235/6023 ,  C04B2235/616 ,  C04B2235/656 ,  C04B2235/6581

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：US20170313629A1

公开(公告)日：2017-11-02

申请号：US15499946

申请日：2017-04-28

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Sungbo Shim ,  Andrew Joseph Lazur ,  Robert Shinavski

IPC: C04B41/00 ,  C04B35/80

Abstract: The disclosure describes techniques for infiltrating a CMC substrate with a first slurry to at least partially fill at least some inner spaces of the CMC substrate, where the first slurry comprises first solid particles, drying the first slurry to form an infiltrated CMC including the first solid particles, depositing a second slurry including a carrier material and second solid particles on a surface of the infiltrated CMC, where the second solid particles comprise a plurality of fine ceramic particles, a plurality of coarse ceramic particles, and a plurality of diamond particles, drying the second slurry to form an article having an outer surface layer comprising the second solid particles on the infiltrated CMC, and infiltrating the article with a molten infiltrant to form a composite article.

公开(公告)号：US20220055957A1

公开(公告)日：2022-02-24

申请号：US17405273

申请日：2021-08-18

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Sungbo Shim ,  Richard Kidd ,  Kelly Kranjc ,  Robert Shinavski

IPC: C04B41/89 ,  C04B35/565 ,  C04B41/00 ,  C04B41/87 ,  C04B41/45 ,  C04B41/50

Abstract: A method of making a ceramic matrix composite that exhibits chemical resistance has been developed. The method comprises depositing a compliant layer comprising boron nitride, silicon-doped boron nitride, and/or pyrolytic carbon on silicon carbide fibers, depositing a barrier layer having a high contact angle with molten silicon on the compliant layer, and depositing a wetting layer comprising silicon carbide, boron carbide, and/or pyrolytic carbon on the barrier layer. After depositing the wetting layer, a fiber preform comprising the silicon carbide fibers is infiltrated with a slurry. After slurry infiltration, the fiber preform is infiltrated with a melt comprising silicon, and then the melt is cooled, thereby forming a ceramic matrix composite.

公开(公告)号：US20220055955A1

公开(公告)日：2022-02-24

申请号：US16997094

申请日：2020-08-19

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Richard Kidd ,  Sungbo Shim ,  Kelly Kranjc ,  Robert Shinavski

IPC: C04B35/80 ,  C04B35/628 ,  C04B35/657 ,  C04B35/65

Abstract: A method of making a ceramic matrix composite that exhibits moisture and environmental resistance has been developed. The method includes depositing a diffusion barrier layer comprising boron nitride on silicon carbide fibers and depositing a moisture-tolerant layer comprising silicon-doped boron nitride on the diffusion barrier layer, where a thickness of the moisture-tolerant layer is from about 3 to about 300 times a thickness of the diffusion barrier layer. Thus, a compliant multilayer including the moisture-tolerant layer and the diffusion barrier layer is formed. A wetting layer comprising silicon carbide, boron carbide, and/or pyrolytic carbon is deposited on the compliant multilayer layer. After depositing the wetting layer, a fiber preform comprising the silicon carbide fibers is infiltrated with a slurry. After slurry infiltration, the fiber preform is infiltrated with a melt comprising silicon and then the melt is cooled, thereby forming a ceramic matrix composite.

公开(公告)号：US11192829B2

公开(公告)日：2021-12-07

申请号：US16539644

申请日：2019-08-13

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

Inventor： Sungbo Shim ,  Robert Wesley Thibault ,  Robert Shinavski ,  Kang N. Lee

IPC: C04B41/89 ,  C04B41/52 ,  C04B35/573 ,  C04B35/626 ,  C04B35/80 ,  C04B41/00 ,  C04B41/45 ,  C04B41/50 ,  C04B41/81 ,  C04B41/85 ,  B33Y10/00

Abstract: The disclosure describes techniques for forming a surface layer of an article including a CMC using a cast. In some examples, the surface layer includes three-dimensional surface features, which may increase adhesion between the CMC and a coating on the CMC. In some examples, the surface layer may include excess material, with or without three-dimensional surface features, which is on the CMC. The excess material may be machined to remove some of the excess material and facilitate conforming the article to dimensional tolerances, e.g., for fitting the article to another component. The excess material may reduce a likelihood that the CMC (e.g., reinforcement material in the CMC) is damaged by the machining.

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：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.