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：US10399911B2

公开(公告)日：2019-09-03

申请号：US15005790

申请日：2016-01-25

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

Inventor： Sungbo Shim ,  Robert Wesley Thibault ,  Robert Shinavski ,  Kang N. Lee

IPC: C04B41/45 ,  C04B41/81 ,  C04B41/52 ,  C04B41/89 ,  C04B41/85 ,  C04B41/50 ,  C04B35/573 ,  C04B35/80 ,  C04B41/00 ,  C04B35/626 ,  B33Y10/00

Abstract: The disclosure describes techniques for forming a surface layer of an article including a CMC using a cast. In some examples, the surface layer includes three-dimensional surface features, which may increase adhesion between the CMC and a coating on the CMC. In some examples, the surface layer may include excess material, with or without three-dimensional surface features, which is on the CMC. The excess material may be machined to remove some of the excess material and facilitate conforming the article to dimensional tolerances, e.g., for fitting the article to another component. The excess material may reduce a likelihood that the CMC (e.g., reinforcement material in the CMC) is damaged by the machining.

公开(公告)号：US20180363132A1

公开(公告)日：2018-12-20

申请号：US16003615

申请日：2018-06-08

Applicant: Rolls-Royce High Temperature Composites Inc.

Inventor： Richard W. Kidd ,  Robert Shinavski

IPC: C23C16/34 ,  C23C16/30 ,  D06M11/58 ,  D06M11/80 ,  F01D25/00

CPC classification number: C23C16/342 ,  C04B35/565 ,  C04B35/62863 ,  C04B35/62868 ,  C04B35/62884 ,  C04B35/62894 ,  C04B35/62897 ,  C04B35/806 ,  C04B2235/3826 ,  C04B2235/46 ,  C04B2235/465 ,  C04B2235/524 ,  C04B2235/5244 ,  C04B2235/616 ,  C23C16/308 ,  D06M11/58 ,  D06M11/80 ,  D06M2101/16 ,  F01D25/005 ,  F05D2300/6033

Abstract: A method of forming a moisture-tolerant coating on a silicon carbide fiber includes exposing a silicon carbide fiber to a gaseous N precursor comprising nitrogen at an elevated temperature, thereby introducing nitrogen into a surface region of the silicon carbide fiber, and exposing the silicon carbide fiber to a gaseous B precursor comprising boron at an elevated temperature, thereby introducing boron into the surface region of the silicon carbide fiber. Silicon-doped boron nitride is formed at the surface region of the silicon carbide fiber without exposing the silicon carbide fiber to a gaseous Si precursor comprising Si. Thus, a moisture-tolerant coating comprising the silicon-doped boron nitride is grown in-situ on the silicon carbide fiber.

公开(公告)号：US20180312442A1

公开(公告)日：2018-11-01

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

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：US20180222807A1

公开(公告)日：2018-08-09

申请号：US15878970

申请日：2018-01-24

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

Inventor： Sungbo Shim ,  Robert Shinavski ,  Ann Bolcavage

IPC: C04B41/45 ,  C04B41/00 ,  C04B41/50 ,  C04B41/51 ,  C04B41/52 ,  C04B41/87 ,  C04B41/88 ,  C23C4/134 ,  C23C4/04 ,  B05D1/18 ,  B05D3/02 ,  C23C4/126

CPC classification number: C04B41/456 ,  B05D1/18 ,  B05D3/0254 ,  C04B41/009 ,  C04B41/4554 ,  C04B41/5001 ,  C04B41/5024 ,  C04B41/5059 ,  C04B41/5133 ,  C04B41/5138 ,  C04B41/52 ,  C04B41/87 ,  C04B41/88 ,  C04B41/89 ,  C23C4/04 ,  C23C4/126 ,  C23C4/134 ,  C23C4/18 ,  F01D5/288 ,  F05D2230/312 ,  F05D2230/90 ,  F05D2300/222 ,  F05D2300/6033 ,  C04B35/80 ,  C04B35/565 ,  C04B35/806 ,  C04B35/584 ,  C04B41/4527 ,  C04B41/4582 ,  C04B41/5096 ,  C04B41/4519 ,  C04B41/4535 ,  C04B41/455 ,  C04B41/4517 ,  C04B41/4558 ,  C04B41/522 ,  C04B41/4537 ,  C04B41/5031 ,  C04B41/5035 ,  C04B41/5023 ,  C04B41/5037 ,  C04B41/5045

Abstract: An example method may include applying a bond coat comprising silicon or a silicon alloy on a surface of a ceramic or ceramic matrix composite substrate, where the bond coat comprises a plurality of pores; infiltrating a precursor into at least some pores of the plurality of pores; and heat-treating the bond coat and the precursor, where after heat-treating a porosity of the bond coat is less than about 5 vol. %, and where after heat-treating, the bond coat is substantially free of continuous porosity extending through a thickness of the bond coat.

公开(公告)号：US09630885B2

公开(公告)日：2017-04-25

申请号：US14864082

申请日：2015-09-24

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

Inventor： Anthony Martin Goetz ,  Robert Shinavski ,  Stephen Isaiah Harris ,  Sean E. Landwehr

IPC: B32B9/00 ,  C04B41/45 ,  C04B41/87 ,  C04B41/85 ,  C04B41/53 ,  C04B41/52 ,  C04B41/50 ,  C04B35/565 ,  C04B35/573 ,  C04B35/626 ,  C04B35/628 ,  C04B35/634 ,  C04B35/636

CPC classification number: C04B35/806 ,  C04B35/565 ,  C04B35/573 ,  C04B35/62281 ,  C04B35/624 ,  C04B35/6261 ,  C04B35/6263 ,  C04B35/6264 ,  C04B35/62857 ,  C04B35/6286 ,  C04B35/62863 ,  C04B35/62865 ,  C04B35/62868 ,  C04B35/62873 ,  C04B35/634 ,  C04B35/636 ,  C04B35/6365 ,  C04B35/65 ,  C04B35/657 ,  C04B41/4584 ,  C04B41/5059 ,  C04B41/5096 ,  C04B41/52 ,  C04B41/53 ,  C04B41/85 ,  C04B41/87 ,  C04B2235/3826 ,  C04B2235/428 ,  C04B2235/48 ,  C04B2235/5224 ,  C04B2235/5228 ,  C04B2235/5232 ,  C04B2235/5236 ,  C04B2235/524 ,  C04B2235/5244 ,  C04B2235/5248 ,  C04B2235/5436 ,  C04B2235/5481 ,  C04B2235/6023 ,  C04B2235/616 ,  C04B2235/656 ,  C04B2235/6581

Abstract: A method of forming a composite article includes impregnating an inorganic fiber preform with a slurry composition. The slurry composition includes a particulate, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to immobilize the particulate and yield a gelled article, and substantially all solvent is removed from the gelled article to form a green composite article. The green composite article is then infiltrated with a molten infiltrant to form the 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：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：US20190389782A1

公开(公告)日：2019-12-26

申请号：US16539644

申请日：2019-08-13

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

Inventor： Sungbo Shim ,  Robert Wesley Thibault ,  Robert Shinavski ,  Kang N. Lee

IPC: C04B41/89 ,  C04B41/52 ,  C04B41/50 ,  C04B41/45 ,  C04B41/00 ,  C04B35/80 ,  C04B35/626 ,  C04B41/85 ,  C04B41/81 ,  C04B35/573

Abstract: The disclosure describes techniques for forming a surface layer of an article including a CMC using a cast. In some examples, the surface layer includes three-dimensional surface features, which may increase adhesion between the CMC and a coating on the CMC. In some examples, the surface layer may include excess material, with or without three-dimensional surface features, which is on the CMC. The excess material may be machined to remove some of the excess material and facilitate conforming the article to dimensional tolerances, e.g., for fitting the article to another component. The excess material may reduce a likelihood that the CMC (e.g., reinforcement material in the CMC) is damaged by the machining.

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.