公开(公告)号：US20220034233A1

公开(公告)日：2022-02-03

申请号：US17501793

申请日：2021-10-14

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 ,  F01D25/00

Abstract: A turbine vane comprising ceramic matrix composite materials includes a vane support core, an airfoil, and an end wall that at least partially defines 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：US11198651B2

公开(公告)日：2021-12-14

申请号：US16227775

申请日：2018-12-20

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Sungbo Shim ,  Camila Bortoluzzi ,  Andrew Phillip Kao

IPC: C04B41/00 ,  C04B41/50 ,  C04B41/52 ,  C04B41/83 ,  C04B41/87 ,  C04B41/89 ,  C04B35/634 ,  C04B35/573 ,  C04B35/626 ,  C04B35/628 ,  C04B41/48

Abstract: The disclosure describes a method for forming a surface layer of a ceramic matrix composite (CMC) article. The technique includes depositing a slurry on a surface of an infiltrated CMC. The slurry includes a carrier material, a binder, a plasticizer, and solid particles. The solid particles include a plurality of fine ceramic particles defining a fine particle average size less than about 5 micrometers. The method further includes drying the slurry to form an article having an outer surface layer that includes the solid particles on the infiltrated CMC. The method further includes machining at least a portion of the outer surface layer of the article. The method further includes infiltrating the article with a molten infiltrant to form a composite article.

公开(公告)号：US11161792B2

公开(公告)日：2021-11-02

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 ,  C04B41/45 ,  B28B13/02 ,  C04B35/626 ,  C04B35/80 ,  F01D5/28

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：US11149568B2

公开(公告)日：2021-10-19

申请号：US16227617

申请日：2018-12-20

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

Inventor： Michael J. Whittle ,  Michael G. Abbott ,  Austin R. Warmuth

IPC: F01D9/04 ,  F01D5/18 ,  F01D5/22 ,  F01D5/28

Abstract: A turbine vane assembly adapted for use in a gas turbine engine includes a support strut and a vane. The support strut is made of metallic materials. The vane is made of composite materials and is arranged around the support strut to insulate the metallic materials of the support strut during use of the turbine vane assembly.

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：US20210189898A1

公开(公告)日：2021-06-24

申请号：US16723249

申请日：2019-12-20

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

Inventor： David J. Thomas ,  Jeffrey A. Walston ,  Aaron D. Sippel ,  Daniel K. Vetters ,  Alexandra Baucco ,  Jeffrey M. Crutchfield

IPC: F01D11/08 ,  F01D25/24 ,  F01D25/00

Abstract: An assembly adapted for use in a gas turbine engine or other engine has a carrier component and a supported component, illustratively used as a heat shield. The assembly includes a mounting system for coupling the supported component to the carrier component. In an illustrative embodiment, the assembly is a turbine shroud segment for blocking gasses from passing over turbine blades included in the gas turbine engine.

公开(公告)号：US20210155558A1

公开(公告)日：2021-05-27

申请号：US17006191

申请日：2020-08-28

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Camila S. Bortoluzzi ,  Sungbo Shim

IPC: C04B41/52 ,  C04B41/45 ,  C04B41/00 ,  C04B41/50 ,  C04B41/51 ,  C04B35/80

Abstract: A method of producing a melt infiltrated ceramic matrix composite (CMC) article that includes the steps of: forming a ceramic fiber preform; optionally, rigidizing the ceramic fiber preform with a fiber interphase coating via a Chemical Vapor Infiltration (CVI) process, infiltrating a ceramic slurry into the porous body or preform, conducting one or more secondary operations, and finally, melt infiltrating the preform with molten silicon or a silicon alloy to form the CMC article. The infiltration of a ceramic slurry into a ceramic fiber preform to form a green body is performed along with the use of convection and/or conduction as heat transfer mechanisms, such that the ceramic slurry does not require the incorporation of a pre-gelation material in order for the slurry to remain within the green body during subsequent processing steps.

公开(公告)号：US20210147303A1

公开(公告)日：2021-05-20

申请号：US17088897

申请日：2020-11-04

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Camila S. Bortoluzzi ,  Sungbo Shim ,  Pathikumar Sellappan

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

Abstract: A method of producing a CMC component that includes forming a preform having a plurality of ceramic fiber plies with each ply occupying a predetermined position; rigidizing the preform with a fiber interphase coating; inspecting the preform to determine which of the plies has partially or fully delaminated; reworking the delaminated plies in the preform; infiltrating a ceramic slurry into the preform to form a green body; optionally, conducting a secondary operation on the green body; and infiltrating the green body with a molten silicon or silicon alloy to form the CMC component. The step of reworking delaminated plies may also be applied to a green body formed after ceramic slurry infiltration into a rigidized fiber preform.

公开(公告)号：US11008652B2

公开(公告)日：2021-05-18

申请号：US16268761

申请日：2019-02-06

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

Inventor： Chong M. Cha ,  David Liliedahl ,  Richard W. Kidd ,  Ross Galligher ,  Nicholas Doan

IPC: C23C16/04 ,  C23C16/24 ,  C23C16/455 ,  C23C16/458 ,  F01D5/28 ,  C23C16/44 ,  C23C16/46 ,  C23C16/52

Abstract: A system may include a reactor vessel comprising an outer wall, a heat source thermally coupled to the reactor vessel, at least one reactor inlet in the outer wall, and at least one reactor outlet. The reactor vessel may be configured to house a porous preform in a radially central core region. The at least one reactor inlet may be configured to introduce a precursor gas to the reactor vessel to produce swirling flow of the precursor gas around the radially central core region of the reactor vessel. The at least one reactor outlet may be configured to remove exhaust gas from the reactor vessel and assist in maintaining a dynamic pressure of the reactor vessel greater than a pressure in the porous preform.

公开(公告)号：US20210108531A1

公开(公告)日：2021-04-15

申请号：US16597495

申请日：2019-10-09

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

Inventor： Daniel K. Vetters ,  Aaron D. Sippel ,  Jeffrey M. Crutchfield ,  Jeffrey A. Walston

IPC: F01D11/08 ,  F01D25/24 ,  F01D9/04

Abstract: A turbine shroud segment of a gas turbine engine includes a carrier segment, a blade track segment, and a plurality of seals arranged between the carrier segment and the blade track segment. The plurality of seals are arranged between the carrier segment and the blade track segment to block gases from passing between the carrier segment and the blade track segment.