Method for producing a surface layer on a ceramic matrix composite
AssigneeRolls-Royce High Temperature Composites Inc.
InventorsPathikumar Sellappan, Sungbo Shim, Kevin Mark Lukhard
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Abstract
A method is provided in which a resin coating is applied to a surface of a preform. The resin coating includes a carbonaceous resin and a particulate. The preform is added to a tooling. The preform, which is positioned in the tooling, is cured. The tooling is removed. The resin coating on the surface of the preform is pyrolyzed to form a resin carbon-char layer on the surface of the preform. The preform and the resin carbon-char layer are infiltrated with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide. During the infiltration, the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform.
Claims20
A method comprising:
- applying a resin coating comprising a carbonaceous resin and a particulate to a surface of a preform;
- controlling a viscosity of the carbonaceous resin, such that the resin coating does not infiltrate the preform;
- adding the preform to a tooling;
- curing the preform positioned in the tooling;
- removing the tooling;
- pyrolyzing the resin coating on the surface of the preform to yield a resin carbon-char layer on the surface of the preform;
- and
- infiltrating the preform and the resin carbon-char layer with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide, wherein during the infiltration the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform.
A method for forming a silicon carbide-rich outer layer on a CMC component, the method comprising:
- applying a resin coating comprising a carbonaceous resin and a particulate to a surface of a preform;
- controlling a viscosity of the carbonaceous resin, such that the resin coating does not infiltrate the preform;
- adding the preform to a tooling after applying the resin coating to the preform, wherein in the tooling is in a shape of at least a portion of a component of a gas turbine engine;
- curing the preform;
- removing the tooling;
- pyrolyzing the resin coating on the surface of the preform to yield a resin carbon-char layer on the surface of the preform;
- and
- after the pyrolyzing, immersing the preform into a molten material, the molten material being infiltrated into the preform.
Dependencies are inferred from the claim text.