Pre-form ceramic matrix composite cavity and method of forming and method of forming a ceramic matrix composite component

A pre-form ceramic matrix composite cavity for a ceramic matrix composite component comprising:

• a cavity conforming to a mandrel geometry;
• a densified base ply defining the cavity;
• and
• at least one densified lay-up ply applied to the densified base ply, the pre-form ceramic matrix composite having a desired geometry and the cavity formed therein.

A method of forming a ceramic matrix composite component comprising:

• providing a lay-up tool having a first surface and a second surface;
• applying a first base ply to the first surface of the lay-up tool;
• laying-up a first set of CMC plies adjacent to the first base ply;
• providing a pre-form ceramic matrix composite cavity comprising:
• a cavity conforming to a mandrel geometry;
• a densified base ply defining the cavity;
• and
• at least one densified lay-up ply applied to the densified base ply, the pre-form ceramic matrix composite cavity having a desired geometry and the cavity formed therein;
• placing the pre-form ceramic matrix composite cavity adjacent to the first set of CMC plies in the lay-up tool;
• laying-up a second set of CMC plies adjacent to the pre-form ceramic matrix composite cavity;
• applying a second base ply to the second set of CMC plies, the second base ply adjacent to the second surface of the lay-up tool;
• and
• densifying the first base ply, the first set of CMC plies, the pre-form ceramic matrix composite cavity, the second set of CMC plies, and the second base ply;
• wherein the ceramic matrix composite is formed having a desired geometry and the cavity formed therein.