公开(公告)号：US20060120874A1

公开(公告)日：2006-06-08

申请号：US11031797

申请日：2005-01-07

申请人： Michael Burke ,  Jay Morrison ,  Steven Vance ,  Daniel Thompson ,  Vijay Parthasarathy ,  Gary Merrill ,  Douglas Keller

发明人： Michael Burke ,  Jay Morrison ,  Steven Vance ,  Daniel Thompson ,  Vijay Parthasarathy ,  Gary Merrill ,  Douglas Keller

IPC分类号： F04D29/38

CPC分类号： F01D5/147 ,  F01D5/284 ,  F04D29/388 ,  F05D2230/23 ,  F05D2300/601 ,  F05D2300/603 ,  F05D2300/614

摘要： A stacked ceramic matrix composite lamellate assembly (10) including shear force bearing structures (48) for resisting relative sliding movement between adjacent lamellae. The shear force bearing structures may take the form of a cross-lamellar stitch (50), a shear pin (62), a warp (90) in the lamellae, a tongue (104) and groove (98) structure, or an inter-lamellar sealing member (112), in various embodiments. Each shear force bearing structure secures a subset of the lamellae, with at least one lamella being common between adjacent subsets in order to secure the entire assembly.

摘要翻译： 一种层叠的陶瓷基复合材料层状组件（10），其包括用于抵抗相邻薄片之间的相对滑动运动的剪切力轴承结构（48）。 剪切力承载结构可以采取跨层状缝合（50），剪切销（62），薄片中的经线（90），舌状物（104）和凹槽（98）结构的形式， - 绝缘密封件（112）。 每个剪切力轴承结构确保薄片的一个子集，其中至少一个薄片在相邻子集之间是共同的，以便固定整个组件。

公开(公告)号：US20050167878A1

公开(公告)日：2005-08-04

申请号：US10767012

申请日：2004-01-29

申请人： Jay Morrison ,  Gary Merrill ,  Steven Vance ,  Michael Burke

发明人： Jay Morrison ,  Gary Merrill ,  Steven Vance ,  Michael Burke

IPC分类号： B28B7/34 ,  B28B11/08 ,  B28B19/00 ,  B29C33/76 ,  B29C39/02 ,  B29C39/12

CPC分类号： B28B7/342 ,  B28B11/08 ,  B28B19/00 ,  C04B2235/6028 ,  F05D2300/6033 ,  Y10S264/44

摘要： A method of manufacturing a hybrid structure (100) having a layer of CMC material (28) defining an interior passageway (24) and a layer of ceramic insulating material (18) lining the passageway. The method includes the step of casting the insulating material to a first thickness required for effective casting but in excess of a desired second thickness for use of the hybrid structure. An inner mold (14) defining a net shape desired for the passageway remains in place after the casting step to mechanically support the insulating material during a machining process used to reduce the thickness of the insulating material from the as-cast first thickness to the desired second thickness. The inner mold also provides support as the CMC material is deposited onto the insulating material. The inner mold may include a fugitive material portion (20) to facilitate its removal after the CMC material is formed.

摘要翻译： 一种制造具有限定内部通道（24）的CMC材料层（28）和衬套通道的陶瓷绝缘材料层（18）的混合结构（100）的方法。 该方法包括将绝缘材料浇铸到有效铸造所需的第一厚度但超过所需的第二厚度以用于混合结构的步骤。 限定通道所需的净形状的内模（14）在铸造步骤之后保持就位，以在用于将绝缘材料的厚度从铸造第一厚度减小到期望的机械加工过程期间机械地支撑绝缘材料 第二厚度。 当CMC材料沉积到绝缘材料上时，内模还提供支撑。 内部模具可以包括短暂材料部分（20），以便在形成CMC材料之后便于其移除。

公开(公告)号：US20070128043A1

公开(公告)日：2007-06-07

申请号：US11040464

申请日：2005-01-21

申请人： Jay Morrison ,  Gary Merrill ,  Steven Vance ,  Harry Albrecht ,  Yevgeniy Shteyman

发明人： Jay Morrison ,  Gary Merrill ,  Steven Vance ,  Harry Albrecht ,  Yevgeniy Shteyman

IPC分类号： F03B3/12

CPC分类号： F01D5/284 ,  F01D5/147 ,  F01D5/282 ,  Y10T29/49337 ,  Y10T29/49339

摘要： An airfoil (44) formed of a plurality of pre-fired structural CMC panels (46, 48, 50, 52). Each panel is formed to have an open shape having opposed ends (54) that are free to move during the drying, curing and/or firing of the CMC material in order to minimize interlaminar stresses caused by anisotropic sintering shrinkage. The panels are at least partially pre-shrunk prior to being joined together to form the desired structure, such as an airfoil (42) for a gas turbine engine. The panels may be joined together using a backing member (30), using flanged ends (54) and a clamp (56), and/or with a bond material (36), for example.

摘要翻译： 由多个预烧结构的CMC板（46,48,50,52）形成的翼型件（44）。 每个板形成为具有相对端（54）的开放形状，其在CMC材料的干燥，固化和/或烧制期间自由移动，以便最小化由各向异性烧结收缩引起的层间应力。 在连接在一起以形成期望的结构之前，板至少部分地预收缩，例如用于燃气涡轮发动机的翼型件（42）。 例如，使用凸缘端部（54）和夹具（56）和/或与粘合材料（36）一起使用背衬构件（30）将面板连接在一起。

公开(公告)号：US20060121296A1

公开(公告)日：2006-06-08

申请号：US11031796

申请日：2005-01-07

申请人： Jay Morrison ,  Daniel Thompson ,  Gary Merrill ,  Jay Lane

发明人： Jay Morrison ,  Daniel Thompson ,  Gary Merrill ,  Jay Lane

IPC分类号： B05D3/02

CPC分类号： F01D5/147 ,  F04D29/388 ,  F05D2230/23 ,  F05D2300/601 ,  F05D2300/603 ,  F05D2300/614

摘要： A thermal barrier layer (20) is formed by exposing an oxide ceramic material to a thermal regiment to create a surface heat affected zone effective to protect an underlying structural layer (18) of the material. The heat affected surface layer exhibits a lower strength and higher thermal conductivity than the underlying load-carrying material; however, it retains a sufficiently low thermal conductivity to function as an effective thermal barrier coating. Importantly, because the degraded material retains the same composition and thermal expansion characteristics as the underlying material, the thermal barrier layer remains integrally connected in graded fashion with the underlying material without an interface boundary there between. This invention is particularly advantageous when embodied in an apparatus formed of an oxide-oxide ceramic matrix composite (CMC) material wherein reinforcing fibers (24) are anchored in the underlying load-carrying portion and extend into the non-structural thermal barrier portion to provide support and to function as surface crack arrestors. In one embodiment an airfoil (10) is formed of a stacked plurality of CMC plates having such a heat-affected thermal barrier layer formed thereon.

摘要翻译： 通过将氧化物陶瓷材料暴露于热团来形成有效保护材料的下面的结构层（18）的表面热影响区域来形成热障层（20）。 受热影响的表层具有比下面的承载材料更低的强度和更高的热导率; 然而，它保持足够低的热导率以用作有效的热障涂层。 重要的是，由于降解的材料保持与下面的材料相同的组成和热膨胀特性，所以热屏障层保持与下面的材料以分级方式整体连接，而其间没有界面边界。 当本发明体现在由氧化物 - 氧化物陶瓷基质复合材料（CMC）材料形成的装置中时，特别有利的是，其中增强纤维（24）锚固在下面的承载部分并延伸到非结构性热障部分中，以提供 支持和作为表面裂纹器。 在一个实施例中，翼片（10）由在其上形成有这种受热影响的热阻挡层的多个CMC板堆叠形成。

公开(公告)号：US20060121265A1

公开(公告)日：2006-06-08

申请号：US11002028

申请日：2004-12-02

申请人： Daniel Thompson ,  Steven Vance ,  Jay Morrison

发明人： Daniel Thompson ,  Steven Vance ,  Jay Morrison

IPC分类号： B32B18/00 ,  B32B17/12 ,  B32B9/00 ,  B32B19/00

CPC分类号： F04D29/388 ,  F01D5/147 ,  F05D2230/23 ,  F05D2300/601 ,  F05D2300/603 ,  F05D2300/614 ,  Y10T428/249928 ,  Y10T428/249929

摘要： Embodiments of the invention relate to a robust turbine vane made of stacked airfoil-shaped CMC laminates. Each laminate has an in-plane direction and a through thickness direction substantially normal to the in-plane direction. The laminates have anisotropic strength characteristics in which the in-plane tensile strength is substantially greater than the through thickness tensile strength. Thus, the laminates can provide strength in the direction of high thermal gradients and, thus, withstand the associated high thermal stresses. The laminates are relatively weak in through thickness (interlaminar) tension, but, in operation, relatively low through thickness tensile stresses can be expected. The laminates can be strong in through thickness compression; accordingly, the laminate stack can be held in through thickness compression by one or more fasteners. The CMC material can permit the inclusion of additional features such as cooling passages, ribs, spars, and thermal coatings, without compromising the strength characteristics of the material.

公开(公告)号：US20070108670A1

公开(公告)日：2007-05-17

申请号：US11649061

申请日：2007-01-03

申请人： Gary Merrill ,  Jay Lane ,  Steven Butner ,  Robert Kreutzer ,  Jay Morrison

发明人： Gary Merrill ,  Jay Lane ,  Steven Butner ,  Robert Kreutzer ,  Jay Morrison

IPC分类号： C04B33/32 ,  B28B1/00

CPC分类号： C04B38/085 ,  B28B11/041 ,  C04B28/00 ,  C04B28/18 ,  C04B28/34 ,  C04B35/117 ,  C04B35/18 ,  C04B35/803 ,  C04B41/009 ,  C04B41/5092 ,  C04B41/85 ,  C04B2235/3217 ,  C04B2235/3463 ,  C04B2235/5228 ,  C04B2235/528 ,  C04B2235/5436 ,  C04B2235/5445 ,  C04B2235/5472 ,  C04B2235/616 ,  Y10T428/249973 ,  C04B20/0036 ,  C04B20/004 ,  C04B14/303 ,  C04B14/306 ,  C04B14/324 ,  C04B14/328 ,  C04B20/0048 ,  C04B20/0076 ,  C04B38/0061 ,  C04B38/08

摘要： A composite material (10) formed of a ceramic matrix composite (CMC) material (12) protected by a ceramic insulating material (14). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material (24) may be used in the insulating material in order to avoid degradation of the fabric (28) of the CMC material during the co-firing step.

摘要翻译： 由陶瓷绝缘材料（14）保护的陶瓷基复合材料（CMC）材料（12）形成的复合材料（10）。 选择绝缘材料的组成部分以避免当两层被共同处理时CMC材料的劣化。 在向CMC材料施加湿绝缘材料之前，将CMC材料加工成预定的收缩状态。 然后将两种材料共烧，在焙烧步骤期间两种材料之间的相对收缩量受到在坯料烧结步骤期间CMC材料的预收缩量的影响。 可以在共烧步骤期间两种材料的收缩率相匹配以最小化收缩应力，或者可以实现材料之间的预定量的预应力。 可以在绝缘材料中使用铝羟基氯化物粘合剂材料（24），以避免在共烧烧步骤期间CMC材料的织物（28）的降解。

公开(公告)号：US20050022921A1

公开(公告)日：2005-02-03

申请号：US10631277

申请日：2003-07-31

申请人： Jay Morrison ,  Gary Merrill ,  Thomas Jackson

发明人： Jay Morrison ,  Gary Merrill ,  Thomas Jackson

IPC分类号： B05B1/00 ,  B32B5/16 ,  C03B29/00 ,  C04B37/00 ,  B32B31/00

CPC分类号： C04B37/005 ,  B32B2315/02 ,  C04B2235/5224 ,  C04B2235/5228 ,  C04B2235/5236 ,  C04B2235/528 ,  C04B2237/062 ,  C04B2237/064 ,  C04B2237/068 ,  C04B2237/34 ,  C04B2237/36 ,  C04B2237/38 ,  C04B2237/592 ,  C04B2237/66 ,  Y10T428/25

摘要： A composite structure (62) having a bond enhancement member (76) extending across a bond joint (86) between a ceramic matrix composite (CMC) material (80) and a ceramic insulation material (82), and a method of fabricating such a structure. The bond enhancement member may extend completely through the CMC material to be partially embedded in a core material (84) bonded to the CMC material on an opposed side from the insulation material. A mold (26) formed of a fugitive material having particles (18) of a bond enhancement material may be used to form the CMC material. A two-piece mold (38, 46) may be used to drive a bond enhancement member partially into the CMC material. A compressible material (56) containing the bond enhancement member may be compressed between a hard tool (60) and the CMC material to drive a bond enhancement member partially into the CMC material. A surface (98) of a ceramic insulation material (92) having a bond enhancement member (96) extending therefrom may be used as a mold for laying up a CMC material.

摘要翻译： 具有穿过陶瓷基体复合材料（CMC）材料（80）和陶瓷绝缘材料（82）之间的接合接头（86）延伸的结合强化构件（76）的复合结构（62），以及制造这种 结构体。 粘结增强构件可以完全延伸穿过CMC材料，以部分地嵌入在与绝缘材料相对的一侧上结合到CMC材料的芯材料（84）中。 由具有粘结增强材料的颗粒（18）的缓冲材料形成的模具（26）可用于形成CMC材料。 可以使用两件式模具（38,46）来将粘结增强部件部分地驱动到CMC材料中。 含有粘结增强部件的可压缩材料（56）可以在硬质工具（60）和CMC材料之间被压缩，以将粘合增强部件部分地驱动到CMC材料中。 陶瓷绝缘材料（92）的表面（98）可以用作用于堆放CMC材料的模具，所述陶瓷绝缘材料（92）的表面（98）具有从其延伸的粘结增强部件（96）。

公开(公告)号：US20060182971A1

公开(公告)日：2006-08-17

申请号：US11059221

申请日：2005-02-16

申请人： Gary Merrill ,  Jay Morrison

发明人： Gary Merrill ,  Jay Morrison

IPC分类号： B32B17/10

CPC分类号： C04B35/80 ,  B32B18/00 ,  C04B2237/32 ,  C04B2237/38 ,  C04B2237/64 ,  Y10T428/24289 ,  Y10T428/249928 ,  Y10T428/31

摘要： A ceramic article having improved interlaminar strength and a method of forming the article. The article may be a ceramic matrix composite article. The methods of forming the articles increase the interlaminar strength of the article by forming indentations in the article during processing. The indentations may be tabs that are formed such that they provide one or more beneficial features for ceramic articles, such as CMC articles and hybrid structures. The tabs may be any of a variety of shapes, orientations, spacings, and combinations. In an alternative embodiment, the indentations are formed by pulling one or more fibers from one side of the ceramic layer to the other side. The articles have increased surface area, which helps to increase the bonding strength between the ceramic layer and any thermal barrier coating layer and/or ceramic core in the ceramic article.

摘要翻译： 具有改善的层间强度的陶瓷制品和形成该制品的方法。 该制品可以是陶瓷基复合制品。 形成制品的方法通过在加工过程中在制品中形成凹痕来增加制品的层间强度。 压痕可以是形成为使得它们为陶瓷制品（例如CMC制品和混合结构）提供一个或多个有益特征的凸片。 翼片可以是各种形状，取向，间距和组合中的任何一个。 在替代实施例中，通过将一个或多个纤维从陶瓷层的一侧拉到另一侧而形成凹口。 制品具有增加的表面积，这有助于增加陶瓷制品中陶瓷层和任何热障涂层和/或陶瓷芯之间的结合强度。

公开(公告)号：US20050254942A1

公开(公告)日：2005-11-17

申请号：US11188406

申请日：2005-07-25

申请人： Jay Morrison ,  Jay Lane ,  Gary Merrill

发明人： Jay Morrison ,  Jay Lane ,  Gary Merrill

IPC分类号： F01D5/28 ,  F01D9/04 ,  F01D1/02

CPC分类号： F01D5/282 ,  B23P15/04 ,  C04B37/001 ,  C04B37/005 ,  C04B2237/341 ,  C04B2237/343 ,  C04B2237/365 ,  C04B2237/38 ,  C04B2237/76 ,  C04B2237/84 ,  F01D5/284 ,  F01D9/044 ,  F05D2230/23 ,  F05D2240/30 ,  Y10T29/49337 ,  Y10T29/49552

摘要： A joining method for assembling components with complex shapes from CMC elements of simpler shapes. A first CMC element (30) is fabricated and fired to a selected first cured state. A second CMC element (36) is fabricated and left in a green state, or is fired to a second partially cured state that is less complete than that of the first cured state. The two CMC elements (30, 36) are joined in a mating interface that captures an inner joining portion (38) of the second element (36) within a surrounding outer joining portion (32) of the first element (30). The assembled elements (30, 36) are then fired together, resulting in differential shrinkage that compresses the outer joining portion (32) onto the inner joining portion (38), providing a tightly pre-stressed joint. Optionally, a refractory adhesive (42) may be used in the joint. Shrinkage of the outer joining portion (32) avoids shrinkage cracks in the adhesive (42).

摘要翻译： 用于从简单形状的CMC元件组装具有复杂形状的部件的接合方法。 制造第一CMC元件（30）并将其烧制至所选择的第一固化状态。 制造第二CMC元件（36）并保持在绿色状态，或者被烧制到比第一固化状态不完全的第二部分固化状态。 两个CMC元件（30,36）连接在配合接口中，该接合接口在第一元件（30）的周围的外部接合部分（32）内捕获第二元件（36）的内部接合部分（38）。 然后将组装好的元件（30,36）烧结在一起，导致不均匀的收缩，将外部接合部分（32）压缩到内部接合部分（38）上，从而提供紧密的预应力接头。 可选地，可以在接头中使用耐火粘合剂（42）。 外接合部分（32）的收缩避免了粘合剂（42）中的收缩裂纹。

公开(公告)号：US20070140835A1

公开(公告)日：2007-06-21

申请号：US11002030

申请日：2004-12-02

申请人： Harry Albrecht ,  Yevgeniy Shteyman ,  Steven Vance ,  Jay Morrison

发明人： Harry Albrecht ,  Yevgeniy Shteyman ,  Steven Vance ,  Jay Morrison

IPC分类号： F03B11/00

CPC分类号： F01D5/147 ,  F01D5/187 ,  F01D5/284 ,  F05D2260/201 ,  F05D2300/501 ,  F05D2300/603 ,  F05D2300/702

摘要： Embodiments of the invention relate to various cooling systems for a turbine vane made of stacked ceramic matrix composite (CMC) laminates. Each airfoil-shaped laminate has an in-plane direction and a through thickness direction substantially normal to the in-plane direction. The laminates have anisotropic strength characteristics in which the in-plane tensile strength is substantially greater than the through thickness tensile strength. Such a vane construction lends itself to the inclusion of various cooling features in individual laminates using conventional manufacturing and forming techniques. When assembled in a radial stack, the cooling features in the individual laminates can cooperate to form intricate three dimensional cooling systems in the vane.

摘要翻译： 本发明的实施例涉及由堆叠的陶瓷基质复合（CMC）层压体制成的涡轮叶片的各种冷却系统。 每个翼型层压板具有基本上垂直于面内方向的面内方向和贯穿厚度方向。 层压板具有各向异性强度特性，其中面内拉伸强度基本上大于贯穿厚度拉伸强度。 这种叶片结构使得能够使用常规的制造和成形技术将各种冷却特征包含在单独的层压板中。 当组装成径向堆叠时，单个层压板中的冷却特征可以协作以在叶片中形成复杂的三维冷却系统。