公开(公告)号：US12152500B2

公开(公告)日：2024-11-26

申请号：US16003627

申请日：2018-06-08

Applicant: General Electric Company

Inventor： Herbert Chidsey Roberts ,  Glenn Curtis Taxacher ,  Timothy P. Coons ,  Jared Hogg Weaver ,  Daniel Gene Dunn ,  Jerome Geoffrey Magnant

IPC: F01D5/00 ,  C04B37/00 ,  C04B41/45 ,  C04B41/81 ,  F01D25/00

Abstract: Composite components and methods for adding a composite material to a composite component are provided. For example, a method comprises positioning a composite material segment against the composite component to form a component layup; applying an insulating material around at least a portion of the component layup to form an insulated layup; and densifying the insulated layup, where the composite component was previously densified before positioning the composite material segment against the composite component. In some embodiments, the composite material is ceramic matrix composite (CMC) and the composite material segment is a plurality of CMC plies. The composite component may be a CMC gas turbine engine component that comprises an original CMC component and a new CMC material segment joined to the original CMC component through the transfer of silicon between the original CMC component and the new CMC material segment during melt infiltration.

公开(公告)号：US11884597B2

公开(公告)日：2024-01-30

申请号：US17851751

申请日：2022-06-28

Applicant: General Electric Company

Inventor： Jerome Geoffrey Magnant ,  Jared Hogg Weaver ,  Daniel Gene Dunn

IPC: B23K1/00 ,  C04B37/00 ,  B23K1/19 ,  B23K103/00

CPC classification number: C04B37/003 ,  B23K1/19 ,  B23K2103/52 ,  C04B2237/086 ,  C04B2237/16 ,  C04B2237/60 ,  C04B2237/61

Abstract: Methods for forming a unitary ceramic component are provided. The method may include: positioning a braze reactant layer in a contact area between a first densified ceramic component and a second densified ceramic component; positioning a pack material around at least a portion of the first densified ceramic component or the second densified ceramic component; positioning at least one infiltrate source in fluid communication with the braze reactant layer; and thereafter, heating the at least one infiltrate source, the pack material, the first densified ceramic component, and the second densified ceramic component to a braze temperature that is at or above a melting point of at least one phase of the infiltrate composition such that at least one phase of infiltrate composition melts and flows into the braze reactant layer and reacts with a ceramic precursor compound therein to form a ceramic material.

公开(公告)号：US20230399266A1

公开(公告)日：2023-12-14

申请号：US17835083

申请日：2022-06-08

Applicant: General Electric Company

Inventor： Joseph John Shiang ,  Jared Hogg Weaver

IPC: C04B35/80 ,  C04B35/76

CPC classification number: C04B35/80 ,  C04B35/76 ,  C04B2235/5252 ,  C04B2235/5268 ,  C04B2235/616

Abstract: Composite components and methods of densifying composite components are provided. For example, a composite component includes a first ply having a first plurality of unidirectional arrays of fiber tows extending in a first direction and a second ply having a second plurality of unidirectional arrays of fiber tows extending in a second direction. A first fluid pathway is defined in the first ply that has a first length greater than a first width, and a second fluid pathway is defined in the second ply that has a second length greater than a second width. The first and second fluid pathways may improve densification of the composite component by improving penetration of a densification fluid in the composite component.

公开(公告)号：US20200308066A1

公开(公告)日：2020-10-01

申请号：US16367884

申请日：2019-03-28

Applicant: General Electric Company

Inventor： Joseph John Shiang ,  Ryan Christopher Mills ,  Jared Hogg Weaver

IPC: C04B35/80 ,  C04B41/45 ,  C04B41/50 ,  C04B35/638 ,  C04B35/634

Abstract: CMC articles and methods for forming CMC articles are provided. In one example aspect, a method for forming a CMC article includes forming a CMC preform defining a first section and a second section. The first section has one or more plies that include sacrificial fibers. The second section of the CMC preform does not include sacrificial fibers. The first and second sections can be laid up to form the CMC prior to thermally processing, e.g., consolidation, firing, and infiltration. When the CMC preform is fired or burned out, the sacrificial fibers are removed or decomposed resulting in formation of channels within the first section of the pyrolyzed CMC preform. The channels are used as gas transport paths during chemical vapor infiltration to facilitate infiltration of a gaseous infiltrant into the fired CMC preform. The channels are then backfilled with a liquid infiltrant during a melt infiltration process.

公开(公告)号：US10774008B2

公开(公告)日：2020-09-15

申请号：US15710954

申请日：2017-09-21

Applicant: General Electric Company

Inventor： Suresh Subramanian ,  Mark Eugene Noe ,  James Dale Steibel ,  Jason David Shapiro ,  Brandon ALIanson Reynolds ,  Kurtis C. Montgomery ,  Jared Hogg Weaver ,  Daniel Gene Dunn

IPC: C04B37/00 ,  C04B35/80 ,  C04B35/657 ,  C04B35/628 ,  F02K9/97 ,  F01D11/08 ,  F01D25/00 ,  F01D5/28 ,  F23R3/00 ,  C04B35/573 ,  F01D9/04 ,  F02K1/82 ,  B32B18/00

Abstract: A ceramic matrix composite article includes a chemical vapor infiltration ceramic matrix composite base portion including ceramic fiber reinforcement material in a ceramic matrix material having between 0% and 5% free silicon. The ceramic matrix composite article further includes a melt infiltration ceramic matrix composite covering portion including a ceramic fiber reinforcement material in a ceramic matrix material having a greater percentage of free silicon than the chemical vapor infiltration ceramic matrix composite base portion.

公开(公告)号：US10597335B2

公开(公告)日：2020-03-24

申请号：US15228693

申请日：2016-08-04

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Daniel Gene Dunn ,  Gregory Scot Corman ,  Jared Hogg Weaver

IPC: C23C16/32 ,  C04B37/00 ,  F01D5/28 ,  F02K9/97 ,  C04B35/573 ,  F01D9/04 ,  C04B35/80 ,  F02K1/82 ,  F01D25/16 ,  C04B35/63 ,  B32B18/00 ,  F01D5/00 ,  F23R3/00

Abstract: Provided is a method including obtaining ceramic matrix composite (CMC) with a first matrix portion including a silicon carbide and silicon phase dispersed therewithin, disposing a coating thereupon to form a sealed part, and forming thereupon another segment comprising a CMC, which may be another matrix portion including a silicon carbide and a silicon phase dispersed within therewithin. Also provided is a gas turbine component with a CMC segment including a matrix portion including a silicon carbide and a silicon phase dispersed therewithin, a sealing layer including silicon carbide enclosing the first segment, and a second segment on the sealing layer, wherein the second segment includes a melt-infiltrated CMC having a matrix portion including a silicon carbide and a silicon phase dispersed therewithin.

公开(公告)号：US10384981B2

公开(公告)日：2019-08-20

申请号：US15622210

申请日：2017-06-14

Applicant: General Electric Company

Inventor： David Bruce Hall ,  James Joseph Murray ,  Jason Robert Parolini ,  Michael Alan Vallance ,  Juan Borja ,  Daniel George Norton ,  Jared Hogg Weaver ,  Daniel Gene Dunn

IPC: C04B35/64 ,  C04B35/80 ,  C04B35/628 ,  C04B35/657 ,  C04B35/117 ,  C04B35/14 ,  C04B35/18 ,  C04B35/44 ,  C04B35/56 ,  C04B35/563 ,  C04B35/573 ,  C04B35/58 ,  C04B35/584 ,  C04B35/83

Abstract: Methods for preparing ceramic matrix composites using melt infiltration and chemical vapor infiltration are provided as well as the resulting ceramic matrix composites. The methods and products include the incorporation of sacrificial fibers to provide improved infiltration of the fluid infiltrant. The sacrificial fibers are removed, such as decomposed during pyrolysis, resulting in the formation of regular and elongate channels throughout the ceramic matrix composite. Infiltration of the fluid infiltrant can then take place using the elongate channels resulting in improved density and an improved ceramic matrix composite product.

公开(公告)号：US20180362413A1

公开(公告)日：2018-12-20

申请号：US15622210

申请日：2017-06-14

Applicant: General Electric Company

Inventor： David Bruce Hall ,  James Joseph Murray ,  Jason Robert Parolini ,  Michael Alan Vallance ,  Juan Borja ,  Daniel George Norton ,  Jared Hogg Weaver ,  Daniel Gene Dunn

IPC: C04B35/80 ,  C04B35/628 ,  C04B35/657 ,  C04B35/64

CPC classification number: C04B35/806 ,  C04B35/117 ,  C04B35/14 ,  C04B35/18 ,  C04B35/44 ,  C04B35/5603 ,  C04B35/5622 ,  C04B35/563 ,  C04B35/573 ,  C04B35/58085 ,  C04B35/584 ,  C04B35/62878 ,  C04B35/64 ,  C04B35/657 ,  C04B35/803 ,  C04B35/83 ,  C04B2235/5212 ,  C04B2235/5224 ,  C04B2235/5228 ,  C04B2235/5232 ,  C04B2235/524 ,  C04B2235/5244 ,  C04B2235/5248 ,  C04B2235/5252 ,  C04B2235/5264 ,  C04B2235/5296 ,  C04B2235/614 ,  C04B2235/616 ,  C04B2235/728 ,  C04B2235/80

Abstract: Methods for preparing ceramic matrix composites using melt infiltration and chemical vapor infiltration are provided as well as the resulting ceramic matrix composites. The methods and products include the incorporation of sacrificial fibers to provide improved infiltration of the fluid infiltrant. The sacrificial fibers are removed, such as decomposed during pyrolysis, resulting in the formation of regular and elongate channels throughout the ceramic matrix composite. Infiltration of the fluid infiltrant can then take place using the elongate channels resulting in improved density and an improved ceramic matrix composite product.

公开(公告)号：US10030305B2

公开(公告)日：2018-07-24

申请号：US14945824

申请日：2015-11-19

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Jared Hogg Weaver ,  Gregory Scot Corman ,  Anteneh Kebbede ,  Daniel Gene Dunn ,  Jerome Geoffrey Magnant

IPC: B44C1/22 ,  C03C15/00 ,  C03C25/68 ,  C23F1/00 ,  C23C16/04

Abstract: A method can include applying a mask to a CMC structure, and subjecting the structure having an applied mask to a process for repair. In one embodiment, the applying a mask to a CMC structure can include applying a mask to a feature of a CMC structure.