Abstract: A ceramic matrix composite article includes a melt infiltration ceramic matrix composite substrate comprising a ceramic fiber reinforcement material in a ceramic matrix material having a free silicon proportion, and a chemical vapor infiltration ceramic matrix composite outer layer comprising a ceramic fiber reinforcement material in a ceramic matrix material having essentially no free silicon proportion disposed on an outer surface of at least a portion of the substrate. FIG. 1
1. A ceramic matrix composite article comprising:
a melt infiltration ceramic matrix composite substrate comprising a ceramic fiber reinforcement material in a ceramic matrix material having a free silicon proportion;
a chemical vapor infiltration ceramic matrix composite outer layer comprising a ceramic fiber reinforcement material in a ceramic matrix material having no free silicon disposed on an outer surface of at least a portion of said substrate.
2. The ceramic matrix composite article as claimed in claim 1 wherein said substrate comprises generally silicon carbide and free silicon, and said outer layer comprises generally pure silicon carbide.
3. The ceramic matrix composite article as claimed in claim 1 wherein said substrate comprises generally silicon carbide and free silicon, and said outer layer comprises generally silicon carbide and free carbon.
4. The ceramic matrix composite article as claimed in claim 1 wherein said substrate comprises a first creep resistance, said outer layer comprises a second creep resistance, and said second creep resistance being greater than said first creep resistance.
5. The ceramic matrix composite article as claimed in claim 1 wherein said substrate comprises a first temperature capability, said outer layer comprises a second temperature capability, and said second temperature capability being greater than said first temperature capability.
6. The ceramic matrix composite article as claimed in claim 1 wherein said substrate comprises a prepreg melt infiltration ceramic matrix composite substrate.
7. The ceramic matrix composite article as claimed in claim 1 wherein said substrate comprises a slurry cast melt infiltration ceramic matrix composite substrate.
8. The ceramic matrix composite article as claimed in claim 1 wherein said ceramic fiber reinforcement material of said substrate comprises a plurality of unidirectional reinforcement fibers.
9. The ceramic matrix composite article as claimed in claim 1 wherein said ceramic fiber reinforcement material of said outer layer comprises at least one layer of unidirectional reinforcement fibers.
10. The ceramic matrix composite article as claimed in claim 1 wherein said ceramic fiber reinforcement material of said outer layer comprises a plurality of layers of unidirectional reinforcement fibers.
11. The ceramic matrix composite article as claimed in claim 1 wherein said cerami fiber reinforcement of said outer layer comprises one or more layers of woven reinforcement fibers.
12. The ceramic matrix composite article as claimed in claim 1 wherein said ceramic fiber reinforcement material of said substrate is the same as said ceramic fiber reinforcement material of said outer layer.
13. The ceramic matrix composite as claimed in claim 1 wherein the CVI composite surface layer is further infiltrated with an oxide material.
14. The ceramic matrix composite article as claimed in claim 1 further comprising an environmental barrier layer disposed on said outer layer.
15. The ceramic matrix composite article as claimed in claim 1 wherein said article is operable at a temperature over 2,400 degrees Fahrenheit.
16. The ceramic matrix composite article as claimed in claim 1 wherein said article comprises a turbine component.
17. A method for forming a ceramic matrix composite article, the method comprising:
forming by melt infiltration a ceramic matrix composite substrate comprising a ceramic fiber reinforcement material in a ceramic matrix material having a free silicon proportion; and
forming by chemical vapor infiltration a ceramic matrix composite outer layer comprising a ceramic fiber reinforcement material in a ceramic matrix material having no free silicon proportion disposed on at least a portion of the substrate.
18. The method as claimed in claim 17 wherein the substrate comprises
generally silicon carbide and free silicon, and the outer layer comprises
generally pure silicon carbide.
19. The method as claimed in claim 17 wherein the substrate comprises generally silicon carbide and free silicon, and the outer layer comprises generally silicon carbide and free carbon.
20. The method as claimed in claim 17 wherein the creep resistance of the outer layer is greater that the creep resistance of the substrate;
21. The method as claimed in claim 17 wherein the temperature capability of the outer layer is greater than the temperature capability of the substrate.
22. The method as claimed in claim 17 wherein the forming the ceramic matrix composite substrate comprise laying up a plurality of prepreg unidirectional tapes.
23. The method as claimed in claim 17 wherein the forming the ceramic matrix composite substrate comprise laying up a plurality of woven fiber plies.
24. The method as claimed in claim 17 wherein the forming the ceramic matrix composite outer layer comprise laying up at least one prepreg unidirectional tape onto the ceramic matrix composite substrate.
25. The method as claimed in claim 17 wherein the forming of the ceramic matrix composite outer layer comprise laying up a plurality of prepreg unidirectional tapes onto the ceramic matrix composite substrate.
26. The method as claimed in claim 17 wherein the forming the ceramic matrix composite outer layer comprise laying up one or more prepreg tapes made from woven fibers onto the ceramic matrix composite substrate.
27. The method as claimed in claim 17 wherein the ceramic fiber reinforcement material of the substrate is the same as the ceramic fiber reinforcement material of the outer layer.
28. The method as claimed in claim 17 wherein the forming the melt infiltration ceramic matrix composite substrate comprises forming by prepreg melt infiltration ceramic matrix composite substrate.
29. The method as claimed in claim 17 wherein the forming the melt infiltration ceramic matrix composite substrate comprises forming a slurry cast melt infiltration ceramic matrix composite substrate.
30. The method as claimed in claim 17 wherein the forming by chemical vapor infiltration the ceramic matrix composite outer layer further comprises annealing the outer layer to increase the crystallinity or grain size of the ceramic matrix material of the outer layer.
31. The method as claimed in claim 17 wherein the forming by melt infiltration the ceramic matrix composite substrate further comprises removing silicon from the surface of the substrate.
| # | Name | Date |
|---|---|---|
| 1 | Power of Attorney [17-02-2016(online)].pdf | 2016-02-17 |
| 2 | Form 5 [17-02-2016(online)].pdf | 2016-02-17 |
| 3 | Form 3 [17-02-2016(online)].pdf | 2016-02-17 |
| 4 | Drawing [17-02-2016(online)].pdf | 2016-02-17 |
| 5 | Description(Complete) [17-02-2016(online)].pdf | 2016-02-17 |
| 6 | abstract 201644005492.jpg | 2016-07-21 |
| 7 | 201644005492-Power of Attorney-050716.pdf | 2016-07-28 |
| 8 | 201644005492-NOTARIZED ASSIGNMENT-050716.pdf | 2016-07-28 |
| 9 | 201644005492-CORRESPONDENCE-NOTARIZED ASSIGNMENT050716.pdf | 2016-07-28 |
| 10 | 201644005492-FORM 18 [30-01-2019(online)].pdf | 2019-01-30 |
| 11 | 201644005492-RELEVANT DOCUMENTS [27-02-2019(online)].pdf | 2019-02-27 |
| 12 | 201644005492-FORM 13 [27-02-2019(online)].pdf | 2019-02-27 |
| 13 | Correspondence by Agent_Power of Attorney_11-03-2019.pdf | 2019-03-11 |
| 14 | 201644005492-FER.pdf | 2020-03-10 |
| 1 | searchE_03-03-2020.pdf |