# US 10,480,108 B2 · Ceramic matrix composite components reinforced for managing multi-axial stresses and methods for fabricating the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,480,108 B2 - Document ID: US10480108B2 - Status: Granted - Kind: B2 - Application number: 15/446,582 - Filed: 2017-03-01 - Published: 2018-09-06 - Granted: 2019-11-19 - Earliest claimed: 2017-03-01 - Assignees: ROLLS-ROYCE plc - Applicants: Rolls-Royce Corporation - Inventors: Jun Shi - Web page: https://patentgrep.com/patent/US10480108B2 ## CPC - D03D 25/005: {Three-dimensional woven fabrics} - B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)} - B22F 5/04: of turbine blades - C04B 35/565: based on silicon carbide - C04B 35/62227: {obtaining fibres} - C04B 35/80: Fibres, filaments, whiskers, platelets, or the like - C22C 47/08: by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould {(C22C47/16 takes precedence)} - C22C 49/14: characterised by the fibres or filaments - C23C 16/00: Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes (reactive sputtering or vacuum evaporation C23C14/00) - D03D 15/242: inorganic, e.g. basalt - D03D 15/573: Tensile strength - F01D 5/187: {Convection cooling} - F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments} - F01D 5/284: {Selection of ceramic materials} - F23R 3/007: {constructed mainly of ceramic components} - C04B 2235/5224: Alumina or aluminates - C04B 2235/5228: Silica and alumina, including aluminosilicates, e.g. mullite - C04B 2235/5236: Zirconia - C04B 2235/5244: Silicon carbide - C04B 2235/5248: Carbon, e.g. graphite - C04B 2235/5252: having a specific pre-form - C04B 2235/5268: Orientation of the fibers - C04B 2235/616: Liquid infiltration of green bodies or pre-forms - D10B 2101/08: Ceramic - D10B 2505/02: Reinforcing materials; Prepregs - F05D 2240/11: Shroud seal segments - F05D 2300/6033: Ceramic matrix composites [CMC] - F05D 2300/6034: Orientation of fibres, weaving, ply angle - F23R 2900/00018: Manufacturing combustion chamber liners or subparts - D03D: WOVEN FABRICS; METHODS OF WEAVING; LOOMS - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - C22C: ALLOYS (treatment of alloys C21D, C22F) - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - F23R: GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS (fluidised bed combustion apparatus specially adapted for operation at superatmospheric pressures F23C10/16) - D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS ## Abstract Ceramic matrix composite components and methods for fabricating ceramic matrix composite components are provided. In one example, a ceramic matrix composite component includes a ceramic matrix composite body. The ceramic matrix composite body includes a layer-to-layer weave of ceramic fibers and a layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers disposed adjacent to the layer-to-layer weave. When stressed, the ceramic matrix composite body forms a relatively high through-thickness stress region and a relatively high in-plane bending stress region. The layer-to-layer weave is disposed through the relatively high through-thickness stress region and the layer of 1D/2D fabric is disposed through the relatively high in-plane bending stress region. ## Claims ### Claim 1 A ceramic matrix composite component, the ceramic matrix composite component comprising: a ceramic matrix composite body comprising a layer-to-layer weave of ceramic fibers and at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers disposed adjacent to the layer-to-layer weave, the ceramic matrix composite body including a relatively high through-thickness stress region and a relatively high in-plane bending stress region, the layer-to-layer weave is disposed through the relatively high through-thickness stress region and the at least one layer of 1D/2D fabric is disposed through the relatively high in-plane bending stress region, wherein the ceramic matrix composite body includes an inside-facing outer surface section and an interior mid-section surrounding the inside-facing outer surface section, and wherein the at least one layer of 1D/2D fabric is disposed in the inside-facing outer surface section and the layer-to-layer weave is disposed in the interior mid-section. ### Claim 2 (depends on 1) The ceramic matrix composite component of claim 1, wherein the layer-to-layer weave comprises a 2.5-dimensional weave of ceramic fibers. ### Claim 3 (depends on 1) The ceramic matrix composite component of claim 1, wherein the layer-to-layer weave comprises a 3-dimensional weave of ceramic fibers. ### Claim 4 (depends on 1) The ceramic matrix composite component of claim 1, wherein the ceramic matrix composite body is a component of a gas turbine engine. ### Claim 5 (depends on 4) The ceramic matrix composite component of claim 4, wherein the ceramic matrix composite body is a seal segment of the gas turbine engine, wherein the inside-facing outer surface section is substantially concave. ### Claim 6 (depends on 4) The ceramic matrix composite component of claim 4, wherein the ceramic matrix composite body is a vane or blade of the gas turbine engine. ### Claim 7 (depends on 6) The ceramic matrix composite component of claim 6, wherein the vane or blade of the gas turbine engine is an internally cooled vane or blade, wherein the inside-facing outer surface section surrounds a cooling channel. ### Claim 8 (depends on 1) The ceramic matrix composite component of claim 1, wherein the relatively high in-plane bending stress region includes a relatively high in-plane tensile stress region and a relatively high in-plane compression stress region, wherein the relatively high through-thickness stress region is disposed between the relatively high in-plane tensile stress region and the relatively high in-plane compression stress region, and wherein the at least one layer of 1D/2D fabric is disposed through the relatively high in-plane tensile stress region. ### Claim 9 (depends on 8) The ceramic matrix composite component of claim 8, wherein the at least one layer of 1D/2D fabric is disposed through the relatively high in-plane compression stress region. ### Claim 10 (depends on 8) The ceramic matrix composite component of claim 8, wherein the layer-to-layer weave is disposed through the relatively high in-plane compression stress region. ### Claim 11 A method for fabricating a ceramic matrix composite component, the method comprising: forming a porous ceramic preform into a ceramic matrix composite body, wherein the porous ceramic preform comprises a layer-to-layer weave of ceramic fibers and at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers by: arranging, the at least one layer of 1D/2D fabric on an inside facing surface of the ceramic matrix composite body in a relatively high in-plane bending stress region of the ceramic matrix composite body; and arranging the layer-to-layer weave in an interior mid-section surrounding the inside-facing outer surface section in a relatively high through-thickness stress region of the ceramic matrix composite body. ### Claim 12 (depends on 11) The method of claim 11, wherein forming the ceramic matrix composite body comprises: infiltrating a molten metal or alloy into the porous ceramic preform; and solidifying the molten metal or alloy to form the ceramic matrix composite body. ### Claim 13 (depends on 11) The method of claim 11, further comprising providing the porous ceramic preform comprising forming a layup that comprises the layer-to-layer weave and the at least one layer of 1D/2D fabric disposed adjacent to the layer-to-layer weave. ### Claim 14 (depends on 13) The method of claim 13, wherein forming the layup comprises arranging the layer-to-layer weave comprising a 2.5-dimensional weave of ceramic fibers in the layup. ### Claim 15 (depends on 13) The method of claim 13, wherein forming the layup comprises arranging the layer-to-layer weave comprising a 3-dimensional weave of ceramic fibers in the layup. ### Claim 16 A ceramic matrix composite component, the ceramic matrix composite component comprising: a ceramic matrix composite body comprising a layer-to-layer weave of ceramic fibers and at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers disposed adjacent to the layer-to-layer weave, the ceramic matrix composite body including a relatively high in-plane bending stress region, the relatively high in-plane bending stress region including a relatively high in-plane tensile stress region, a relatively high in-plane compression stress region, wherein the at least one layer of 1-directional and/or 2-directional (1D/2D) fabric of ceramic fibers is disposed in the relatively high in-plane tensile stress region and the layer-to-layer weave is disposed in the relatively high in-plane compression stress region. ### Claim 17 (depends on 16) The ceramic matrix composite component of claim 16, wherein a relatively high through-thickness stress region disposed between the relatively high in-plane tensile stress region and the relatively high in-plane compression stress region. ### Claim 18 (depends on 17) The ceramic matrix composite component of claim 17, wherein the ceramic matrix composite body has an outer surface section and an interior mid-section that is disposed adjacent to the outer surface section, wherein the at least one layer of 1D/2D fabric is disposed in the outer surface section of the ceramic matrix composite body, and wherein the layer-to-layer weave is disposed in the interior mid-section of the ceramic matrix composite body. ### Claim 19 (depends on 16) The ceramic matrix composite component of claim 16, wherein ceramic matrix composite body is a non-internally cooled vane or blade of a gas turbine engine having an outer surface section that surrounds a substantially solid interior mid-section, and wherein the at least one layer of 1D/2D fabric is disposed in the outer surface section and the layer-to-layer weave is disposed in the substantially solid interior mid-section of the non-internally cooled vane or blade. ### Claim 20 (depends on 16) The ceramic matrix composite component of claim 16, wherein the ceramic matrix composite body is an annular ceramic matrix composite combustor of a gas turbine engine, wherein the annular ceramic matrix composite combustor has an interior mid-section surrounding a cooling channel and an outside-facing outer surface section that surrounds the interior mid-section, and wherein the at least one layer of 1D/2D fabric is disposed in the outside-facing outer surface section and the layer-to-layer weave is disposed in the interior mid-section of the annular ceramic matrix composite combustor.