# US 12,110,256 B2 · Method for manufacturing a part made from CMC

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- Number: US 12,110,256 B2
- Document ID: US12110256B2
- Status: Granted
- Kind: B2
- Application number: 17/265,359
- Filed: 2019-07-23
- Published: 2021-09-23
- Granted: 2024-10-08
- Earliest claimed: 2018-08-03
- Assignees: Safran Ceramics
- Applicants: Safran Ceramics
- Inventors: Eric Bouillon; Eric Philippe; Gildas Garnier; Maxime François Roger Carlin; Michael Verrilli
- Web page: https://patentgrep.com/patent/US12110256B2

## CPC

- C04B 35/80: Fibres, filaments, whiskers, platelets, or the like
- B29C 70/24: oriented in at least three directions forming a three-dimensional [3D] structure
- C04B 35/563: based on boron carbide
- C04B 35/565: based on silicon carbide
- C04B 35/571: obtained from {Si-containing} polymer precursors {or organosilicon monomers}
- C04B 35/58092: {based on refractory metal silicides}
- C04B 35/584: based on silicon nitride
- C04B 35/62863: {Silicon carbide}
- C04B 35/62868: {Boron nitride}
- C04B 35/62873: {Carbon}
- C04B 35/83: Carbon fibres in a carbon matrix
- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- F01D 5/284: {Selection of ceramic materials}
- B29B 11/16: comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)}
- C04B 2235/3821: Boron carbides
- C04B 2235/3826: Silicon carbides
- C04B 2235/386: Boron nitrides
- C04B 2235/3873: Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
- C04B 2235/3891: Silicides, e.g. molybdenum disilicide, iron silicide
- C04B 2235/5244: Silicon carbide
- C04B 2235/5248: Carbon, e.g. graphite
- C04B 2235/5268: Orientation of the fibers
- C04B 2235/612: Machining
- C04B 2235/614: Gas infiltration of green bodies or pre-forms
- C04B 2235/616: Liquid infiltration of green bodies or pre-forms
- F05D 2300/224: Carbon, e.g. graphite
- F05D 2300/6033: Ceramic matrix composites [CMC]
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- 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
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A process for manufacturing a part made of composite material with a matrix at least predominantly made of ceramic includes producing a fibrous structure by three-dimensional or multilayer weaving; shaping the fibrous structure to form a fibrous preform core; depositing an interphase on the fibers of the preform core; consolidating the preform core by partial densification of the core including the formation of a matrix phase by chemical vapor infiltration or by a liquid process; depositing a powder of ceramic particles in the porosity of the preform core; draping one or more layers of pre-impregnated non-woven fibers over all or part of the outer surface of the preform core; heat treatment of the preform core and of the pre-impregnated layer(s) to form a hybrid fibrous preform; further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon to obtain a ceramic matrix composite part.

## Claims

### Claim 1

A process for manufacturing a part made of a composite material with a matrix at least predominantly made of ceramic, the process comprising:
producing a fibrous structure by three-dimensional or multilayer weaving;
shaping the fibrous structure to form a fibrous preform core;
depositing an interphase on the fibers of the preform core;
consolidating the preform core by partial densification of said core comprising the formation of a matrix phase by chemical vapor infiltration or by a liquid process;
depositing a powder of ceramic particles in a porosity of the preform core;
wherein, said process comprises, after the steps of producing, shaping, depositing, consolidating and depositing, the following steps:
draping one or more layers of pre-impregnated non-woven fibers over all or part of the outer surface of the preform core;
performing a heat treatment of the preform core and of the pre-impregnated layer(s) to form a hybrid fibrous preform;
further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon in order to obtain a ceramic matrix composite part.

### Claim 2 (depends on 1)

The process as claimed in claim 1, wherein the fibrous structure intended to form the preform core is woven with silicon carbide fiber threads or carbon fibers.

### Claim 3 (depends on 1)

The process as claimed in claim 1, wherein the interphase consists of pyrolytic carbon or of boron nitride.

### Claim 4 (depends on 1)

The process as claimed in claim 1, wherein, during consolidation, the matrix phase is formed in the preform core by chemical vapor infiltration, the matrix phase corresponding to a silicon carbide matrix or a self-healing matrix.

### Claim 5 (depends on 1)

The process as claimed in claim 1, further comprising, after the consolidation of the preform core, machining the preform core.

### Claim 6 (depends on 1)

The process as claimed in claim 1, wherein the ceramic material of the particles deposited in the porosity of the preform core is selected from one of the following materials or a mixture of the following materials: silicon carbide, silicon nitride, titanium silicide, boron carbide and carbon.

### Claim 7 (depends on 1)

The process as claimed in claim 1, wherein the pre-impregnated non-woven layer(s) are formed from silicon carbide or carbon carbide fiber threads.

### Claim 8 (depends on 1)

The process as claimed in claim 1, wherein the pre-impregnated non-woven layers are unidirectional layers of continuous fibers or layers of discontinuous fibers.

### Claim 9 (depends on 1)

The process as claimed in claim 1, wherein the non-woven layers are pre-impregnated with a carbon or silicon carbide precursor resin, the heat treatment comprising a polymerization treatment of the resin and a pyrolysis treatment to convert the precursor to carbon or to silicon carbide.

### Claim 10 (depends on 1)

A method comprising performing the process as claimed in claim 1 to the manufacture of a gas turbine blade, nozzle or combustor.

### Claim 11 (depends on 1)

The process as claimed in claim 1, wherein the depositing the powder of ceramic particles in the porosity of the preform core comprises impregnating the preform core with a slurry containing at least one powder of ceramic particles.

### Claim 12 (depends on 1)

The process as claimed in claim 1, wherein the slurry further comprises one or more organic binders.

### Claim 13

A process for manufacturing a ceramic matrix composite part with a matrix at least predominantly made of ceramic, the process comprising, in order:
producing a fibrous structure by three-dimensional or multilayer weaving;
shaping the fibrous structure to form a fibrous preform core;
depositing an interphase on the fibers of the preform core;
consolidating the preform core by partial densification of said core comprising the formation of a matrix phase by chemical vapor infiltration or by a liquid process, such that the preform core remains porous and has a residual porosity;
depositing a powder of ceramic particles in the residual porosity of the preform core;
draping one or more layers of pre-impregnated non-woven fibers over at least part of an outer surface of the preform core;
performing a heat treatment of the preform core and of the one or more layers of pre-impregnated non-woven fibers to form a hybrid fibrous preform;
further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon in order to obtain the ceramic matrix composite part.