公开(公告)号：US12233572B2

公开(公告)日：2025-02-25

申请号：US17015840

申请日：2020-09-09

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Pathikumar Sellappan ,  Sungbo Shim

IPC: B28B11/24 ,  C04B35/64

Abstract: Methods of reducing dry crack formation in ceramic matrix composite green bodies are provided. Some of the methods expose the green body to a gaseous atmosphere at a relatively high humidity for a first period, and then slowly lower the humidity over a second period, where the gaseous atmosphere is at room temperature for both periods. Other methods start the gaseous atmosphere at room temperature and then raise the temperature to a higher temperature while the humidity is relatively high, and hold that temperature even as the humidity is lowered in the second period.

公开(公告)号：US12078417B1

公开(公告)日：2024-09-03

申请号：US17646419

申请日：2021-12-29

Applicant: Rolls-Royce High Temperature Composites, Inc.

Inventor： Jeffrey Crutchfield

IPC: F27B14/08 ,  F27B14/12

CPC classification number: F27B14/0806 ,  F27B14/12

Abstract: In various aspects, a preheater, a directed flow chemical vapor infiltration/chemical vapor deposition (CVI/CVD) furnace, and/or an installation jig are described. In one example, a preheater includes a central inlet; a circuitous gas flow path downstream of the central inlet; a plenum section downstream of the circuitous gas flow path; and an outlet diffuser plate defining a plurality of apertures fluidly configured to couple the preheater to a furnace working zone, wherein the outlet diffuser plate is downstream of the plenum section, wherein the circuitous gas flow path is fluidly coupled to the plenum section by an outer circumferential slot opening.

公开(公告)号：US11820716B2

公开(公告)日：2023-11-21

申请号：US16655565

申请日：2019-10-17

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

Inventor： Ted Freeman ,  Aaron Sippel ,  Robert Shinavski ,  Chris Barrett

IPC: C04B35/573 ,  C04B35/628 ,  C04B35/80

CPC classification number: C04B35/573 ,  C04B35/62863 ,  C04B35/62884 ,  C04B35/80 ,  C04B2235/3826 ,  C04B2235/5244 ,  C04B2235/5256 ,  C04B2235/614 ,  C04B2235/945

Abstract: A method of fabricating cooling features on a CMC component may comprise compressing a fabric preform within tooling including holes and/or recesses facing the fabric preform. During the compression, portions of the fabric preform are pushed into the holes and/or recesses. Gases are delivered through the tooling to deposit a matrix material on exposed surfaces of the fabric preform while the fabric preform is being compressed. The matrix material builds up on the portions of the fabric preform pushed into the holes and/or recesses, and a rigidized preform with surface protrusions is formed. The tooling is removed, and the rigidized preform is densified, thereby forming a CMC component including raised surface features.

公开(公告)号：US11731910B1

公开(公告)日：2023-08-22

申请号：US17514744

申请日：2021-10-29

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Richard Kidd

IPC: C04B35/80 ,  C04B35/628 ,  C04B35/626 ,  C04B35/657 ,  C04B35/65

CPC classification number: C04B35/80 ,  C04B35/6265 ,  C04B35/62849 ,  C04B35/62868 ,  C04B35/62873 ,  C04B35/62884 ,  C04B35/62892 ,  C04B35/62897 ,  C04B35/65 ,  C04B35/657 ,  C04B2235/3826 ,  C04B2235/428 ,  C04B2235/5244 ,  C04B2235/5256 ,  C04B2235/614 ,  C04B2235/616 ,  C04B2235/6567 ,  C04B2235/6583

Abstract: A method of making a ceramic matrix composite (CMC) that may show improved resistance to chemical attack from molten silicon along with excellent mechanical strength is described. The method includes forming an interphase coating on one or more silicon carbide fibers, depositing a matrix layer comprising silicon carbide on the interphase coating, oxidizing the matrix layer to form an oxidized film comprising silicon oxide, depositing a wetting layer comprising silicon carbide on the oxidized film. After depositing the wetting layer, a fiber preform containing the silicon carbide fibers is heat treated. After the heat treatment, the fiber preform is infiltrated with a slurry. After infiltration with the slurry, the fiber preform is infiltrated with a melt containing silicon, and then the melt is cooled to form a ceramic matrix composite.

公开(公告)号：US11434175B2

公开(公告)日：2022-09-06

申请号：US16890203

申请日：2020-06-02

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

Inventor： Jun Shi ,  Sungbo Shim

IPC: C04B35/628 ,  C04B41/45 ,  C25D9/04 ,  C04B35/622

Abstract: An electrophoretic deposition method of forming a boron nitride (BN) nanotube interface coating on ceramic fibers has been developed. The method comprises immersing first and second electrodes in a suspension including surface-modified BN nanotubes, where the first electrode includes ceramic fibers positioned on a surface thereof. The surface-modified BN nanotubes comprise BN nanotubes with an electrically charged polymer adsorbed on surfaces thereof. A voltage is applied to the first and second electrodes, and the surface-modified BN nanotubes move toward the first electrode and deposit on the ceramic fibers. After the deposition of the surface-modified BN nanotubes, the ceramic fibers are removed from the suspension and heat treated. Accordingly, a BN nanotube interface coating is formed on the ceramic fibers.

公开(公告)号：US20220169574A1

公开(公告)日：2022-06-02

申请号：US17412686

申请日：2021-08-26

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Sungbo Shim ,  Pathikumar Sellappan

IPC: C04B35/80 ,  C04B35/657 ,  C04B35/628 ,  C04B35/626 ,  F01D5/28 ,  F01D25/00

Abstract: A method to form a machinable ceramic matrix composite comprises forming a porous ceramic multilayer on a surface of a fiber preform. In one example, the porous ceramic multilayer comprises a gradient in porosity in a direction normal to the surface. In another example, the porous ceramic multilayer includes low-wettability particles having a high contact angle with molten silicon, where an amount of the low-wettability particles in the porous ceramic multilayer varies in a direction normal to the surface. After forming the porous ceramic multilayer, the fiber preform is infiltrated with a melt, and the melt is cooled to form a ceramic matrix composite with a surface coating thereon. An outer portion of the surface coating is more readily machinable than an inner portion of the surface coating. The outer portion of the surface coating is machined to form a ceramic matrix composite having a machined surface with a predetermined surface finish and/or dimensional tolerance.

公开(公告)号：US20220154582A1

公开(公告)日：2022-05-19

申请号：US17592226

申请日：2022-02-03

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

Inventor： Michael J. Whittle ,  Louise J. Gale ,  Stephan J. Pattison ,  Anthony G. Razzell ,  Ian M. Edmonds ,  Michael G. Abbott

IPC: F01D5/28 ,  F01D5/14 ,  F01D9/04

Abstract: A method of treating a component adapted for use in a gas turbine engine is described herein. The component may comprise ceramic matrix composite materials. The treatment to the ceramic matrix composite component may reduce or eliminate the wear or damage of crack propagation in the ceramic matrix composite component.

公开(公告)号：US20210403389A1

公开(公告)日：2021-12-30

申请号：US17166273

申请日：2021-02-03

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

Inventor： Sungbo Shim ,  Kang N. Lee ,  Stephen Isaiah Harris ,  Andrew Joseph Lazur

IPC: C04B37/00 ,  C23C28/00 ,  F01D5/28 ,  C04B41/89 ,  C23C20/04 ,  C04B41/00 ,  C04B41/85 ,  C04B41/45 ,  C04B41/50 ,  C04B41/52

Abstract: In some examples, a method may include depositing, from a slurry comprising particles including silicon metal, a bond coat precursor layer including the particles comprising silicon metal directly on a ceramic matrix composite substrate. The method also may include locally heating the bond coat precursor layer to form a bond coat comprising silicon metal. Additionally, the method may include forming a protective coating on the bond coat. In some examples, an article may include a ceramic matrix composite substrate, a bond coat directly on the substrate, and a protective coating on the bond coat. The bond coat may include silicon metal and a metal comprising at least one of Zr, Y, Yb, Hf, Ti, Al, Cr, Mo, Nb, Ta, or a rare earth metal.

公开(公告)号：US11198276B2

公开(公告)日：2021-12-14

申请号：US16277189

申请日：2019-02-15

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

Inventor： Sungbo Shim ,  Benjamin Lai

IPC: B32B18/00 ,  C04B35/626 ,  C04B35/628 ,  C04B35/573 ,  C04B35/80

Abstract: A method of forming a ceramic matrix composite (CMC) component having an engineered surface includes applying a surface slurry comprising first particulate solids in a liquid carrier to an outer surface of a ceramic fiber preform. The surface slurry is dried to remove the liquid carrier, and thus a surface slurry layer comprising the first particulate solids is formed on the outer surface. The surface slurry layer is polished to a predetermined thickness and/or surface finish. After polishing, a ceramic tape comprising second particulate solids is applied to the surface slurry layer, and pressure is applied to attach the ceramic tape to the surface slurry layer and to induce consolidation of the ceramic tape and the surface slurry layer. Thus, a multilayer surface region comprising the surface slurry layer and a ceramic tape layer is formed on the ceramic fiber preform. The ceramic fiber preform and the multilayer surface region are infiltrated with a molten material, and, upon cooling, a CMC component having an engineered surface is formed.

公开(公告)号：US11187098B2

公开(公告)日：2021-11-30

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.