公开(公告)号：US11434176B2

公开(公告)日：2022-09-06

申请号：US16111508

申请日：2018-08-24

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Stephen Harris

IPC: C04B35/638 ,  C04B35/80 ,  D02G3/44 ,  D02J13/00 ,  D02J1/08 ,  C04B35/622 ,  C04B35/628 ,  D02G3/04 ,  B29C70/18 ,  D02J1/18 ,  B29C70/30 ,  B29C70/36

Abstract: A method of making a ceramic fiber tow and the system regarding the same may be included. The method may include commingling a plurality of ceramic fibers with a fugitive fiber to form a single ceramic fiber tow. The fugitive fiber may be positioned between at least two ceramic fibers included in the single ceramic fiber tow. The method may further include forming a porous ceramic preform including at least the single ceramic fiber tow. The method may further include removing the fugitive fiber from the ceramic fiber tow leaving a space between at least two ceramic fibers of the single ceramic fiber tow. The method may further include replacing the spaces between ceramic fibers included in the ceramic fiber tows with a ceramic matrix.

公开(公告)号：US11046618B2

公开(公告)日：2021-06-29

申请号：US15967664

申请日：2018-05-01

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

Inventor： Robert Shinavski ,  Joseph Doyle ,  Andrew Ritchey ,  Stephen Harris

IPC: C23C2/00 ,  C04B35/80 ,  C04B35/628 ,  C04B35/657 ,  C04B35/573 ,  C04B35/64

Abstract: A ceramic matrix composite (CMC) is formed by infiltrating a metal or alloy into a fiber preform in a reactor or furnace that is separated into multiple discrete temperature zones. The gradual cooling of the CMC is controlled, such that upon solidification, a narrow, planar, solidification front is created which allows the expanding metal or alloy to move into a hotter section of the fiber preform, opposed to the surface of the CMC. A discrete solidification front is established that moves through the ceramic matrix composite (CMC) as the composite cools.

公开(公告)号：US10759711B2

公开(公告)日：2020-09-01

申请号：US15995537

申请日：2018-06-01

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Stephen Harris

IPC: C04B35/571 ,  C04B35/80 ,  C04B35/565 ,  C04B35/58 ,  C04B35/10 ,  C04B35/18 ,  C04B35/563 ,  F01D5/28 ,  C04B35/573 ,  C04B41/00 ,  C04B41/87 ,  C04B41/50 ,  F23R3/00

Abstract: A method of controllably coating a fiber preform has been developed. The method includes infiltrating a fiber preform with a first solvent to form a solvent-filled preform. After the infiltration, a slurry is applied to one or more outer surfaces of the solvent-filled preform to form a slurry coating thereon. The slurry coating comprises particulate solids dispersed in a second solvent having a vapor pressure higher than that of the first solvent. The slurry coating and the solvent-filled preform are dried. During drying, the second solvent evaporates from the slurry coating before the first solvent evaporates from the solvent-filled preform. The slurry coating dries to form a porous surface coating comprising the particulate solids on the one or more outer surfaces of the solvent-filled preform. The drying of the solvent-filled preform continues after formation of the porous surface coating to remove the first solvent.

公开(公告)号：US09856176B2

公开(公告)日：2018-01-02

申请号：US15247167

申请日：2016-08-25

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Stephen Harris ,  Robert Shinavski

IPC: C04B35/628 ,  C04B35/80 ,  C04B35/657 ,  C04B35/622 ,  C04B35/56 ,  C04B35/565 ,  C04B35/58 ,  F01D5/28 ,  F23R3/00

CPC classification number: C04B35/803 ,  C04B35/5607 ,  C04B35/5615 ,  C04B35/5618 ,  C04B35/5622 ,  C04B35/565 ,  C04B35/58007 ,  C04B35/58014 ,  C04B35/58028 ,  C04B35/62277 ,  C04B35/62863 ,  C04B35/62868 ,  C04B35/62873 ,  C04B35/62884 ,  C04B35/62894 ,  C04B35/657 ,  C04B35/806 ,  C04B2235/3826 ,  C04B2235/3843 ,  C04B2235/3891 ,  C04B2235/428 ,  C04B2235/44 ,  C04B2235/5244 ,  C04B2235/5256 ,  C04B2235/5436 ,  C04B2235/606 ,  C04B2235/608 ,  C04B2235/616 ,  C04B2235/728 ,  C04B2235/77 ,  C04B2235/80 ,  F01D5/282 ,  F01D5/284 ,  F05D2240/11 ,  F05D2300/222 ,  F05D2300/6033 ,  F23M5/00 ,  F23M2900/05004 ,  F23R3/007

Abstract: A ceramic matrix composite includes continuous silicon carbide fibers in a ceramic matrix comprising silicon carbide and a MAX phase compound having a chemical composition Mn+1AXn, where M is a transition metal selected from the group consisting of: Ti, V, Cr, Sc, Zr, Nb, Mo, Hf, and Ta; A is a group-A element selected from the group consisting of: Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, Tl and Pb; and X is carbon or nitrogen, with n being an integer from 1 to 3.

公开(公告)号：US11834956B2

公开(公告)日：2023-12-05

申请号：US17557026

申请日：2021-12-20

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

Inventor： Michael J. Whittle ,  Stephen Harris

IPC: F01D25/14 ,  F01D11/08 ,  F01D5/28 ,  F01D5/14 ,  F01D5/18

CPC classification number: F01D25/145 ,  F01D5/147 ,  F01D5/18 ,  F01D5/28 ,  F01D11/08 ,  F05D2240/11 ,  F05D2260/231 ,  F05D2300/612

Abstract: A turbine shroud assembly for a gas turbine engine includes a shroud wall extending circumferentially partway around a central reference axis to define a gas path of the gas turbine engine. An attachment feature extends radially from the shroud wall. A foam is located at least on the shroud wall.

公开(公告)号：US11504813B2

公开(公告)日：2022-11-22

申请号：US16876834

申请日：2020-05-18

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

Inventor： Michael J. Whittle ,  Stephen Harris ,  Keith Sadler ,  Matthew D. Thomason ,  Andrew Norton ,  James Kell

IPC: B23P6/00 ,  F01D5/00 ,  F01D5/28 ,  G01M15/14

Abstract: A method comprises inspecting a ceramic matrix composite component assembled in a gas turbine engine to determine an extent of damage to the ceramic matrix composite component, determining a repair technique to repair the damage to the ceramic matrix composite component based on the extent of damage to the ceramic matrix composite component, and repairing the ceramic matrix composite component using the repair technique.

公开(公告)号：US20210354253A1

公开(公告)日：2021-11-18

申请号：US16876834

申请日：2020-05-18

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

Inventor： Michael J. Whittle ,  Stephen Harris ,  Keith Sadler ,  Matthew D. Thomason ,  Andrew Norton ,  James Kell

IPC: B23P6/00 ,  G01M15/14 ,  F01D5/00 ,  F01D5/28

Abstract: A method comprises inspecting a ceramic matrix composite component assembled in a gas turbine engine to determine an extent of damage to the ceramic matrix composite component, determining a repair technique to repair the damage to the ceramic matrix composite component based on the extent of damage to the ceramic matrix composite component, and repairing the ceramic matrix composite component using the repair technique.

公开(公告)号：US20190185385A1

公开(公告)日：2019-06-20

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 ,  C08J5/24 ,  C08J5/12 ,  C04B35/628 ,  C04B35/634 ,  C04B35/638 ,  C04B35/657 ,  B32B5/02 ,  B32B9/00 ,  B32B37/15 ,  B32B38/00

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：US20190177240A1

公开(公告)日：2019-06-13

申请号：US16111508

申请日：2018-08-24

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Stephen Harris

IPC: C04B35/80 ,  D02G3/04 ,  D02G3/44 ,  D02J13/00 ,  D02J1/08 ,  C04B35/622 ,  C04B35/628

Abstract: A method of making a ceramic fiber tow and the system regarding the same may be included. The method may include commingling a plurality of ceramic fibers with a fugitive fiber to form a single ceramic fiber tow. The fugitive fiber may be positioned between at least two ceramic fibers included in the single ceramic fiber tow. The method may further include forming a porous ceramic preform including at least the single ceramic fiber tow. The method may further include removing the fugitive fiber from the ceramic fiber tow leaving a space between at least two ceramic fibers of the single ceramic fiber tow. The method may further include replacing the spaces between ceramic fibers included in the ceramic fiber tows with a ceramic matrix.

公开(公告)号：US20170057879A1

公开(公告)日：2017-03-02

申请号：US15247167

申请日：2016-08-25

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Stephen Harris ,  Robert Shinavski

IPC: C04B35/80 ,  C04B35/622 ,  C04B35/657

CPC classification number: C04B35/803 ,  C04B35/5607 ,  C04B35/5615 ,  C04B35/5618 ,  C04B35/5622 ,  C04B35/565 ,  C04B35/58007 ,  C04B35/58014 ,  C04B35/58028 ,  C04B35/62277 ,  C04B35/62863 ,  C04B35/62868 ,  C04B35/62873 ,  C04B35/62884 ,  C04B35/62894 ,  C04B35/657 ,  C04B35/806 ,  C04B2235/3826 ,  C04B2235/3843 ,  C04B2235/3891 ,  C04B2235/428 ,  C04B2235/44 ,  C04B2235/5244 ,  C04B2235/5256 ,  C04B2235/5436 ,  C04B2235/606 ,  C04B2235/608 ,  C04B2235/616 ,  C04B2235/728 ,  C04B2235/77 ,  C04B2235/80 ,  F01D5/282 ,  F01D5/284 ,  F05D2240/11 ,  F05D2300/222 ,  F05D2300/6033 ,  F23M5/00 ,  F23M2900/05004 ,  F23R3/007

Abstract: A ceramic matrix composite includes continuous silicon carbide fibers in a ceramic matrix comprising silicon carbide and a MAX phase compound having a chemical composition Mn+1AXn, where M is a transition metal selected from the group consisting of: Ti, V, Cr, Sc, Zr, Nb, Mo, Hf, and Ta; A is a group-A element selected from the group consisting of: Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, Tl and Pb; and X is carbon or nitrogen, with n being an integer from 1 to 3.

Abstract translation: 陶瓷基复合材料包括在包含碳化硅的陶瓷基体中的连续碳化硅纤维和化学组成为Mn + 1A×n的最大相化合物，其中M是选自Ti，V，Cr，Sc， Zr，Nb，Mo，Hf和Ta; A是选自Al，Si，P，S，Ga，Ge，As，Cd，In，Sn，Tl和Pb中的A族元素; 且X为碳或氮，n为1至3的整数。