# US 2014/0193577 A1 · Pre-form ceramic matrix composite cavity and method of forming and method of forming a ceramic matrix composite component > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0193577 A1 - Document ID: US20140193577A1 - Status: Published application - Kind: A1 - Application number: 13/446,465 - Filed: 2012-04-13 - Published: 2014-07-10 - Earliest claimed: 2012-04-13 - Assignees: General Electric Company - Inventors: Philip Harold MONAGHAN; John McConnell DELVAUX; Glenn Curtis TAXACHER - Web page: https://patentgrep.com/patent/US20140193577A1 ## CPC - B29D 99/0028: {hollow blades} - C04B 35/80: Fibres, filaments, whiskers, platelets, or the like - B28B 23/0006: {the reinforcement consisting of aligned, non-metal reinforcing elements} - B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products - C04B 35/565: based on silicon carbide - F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments} - F01D 5/284: {Selection of ceramic materials} - C04B 2235/5244: Silicon carbide - C04B 2235/6026: Computer aided shaping, e.g. rapid prototyping - C04B 2237/341: Silica or silicates - C04B 2237/343: Alumina or aluminates - C04B 2237/36: Non-oxidic - C04B 2237/361: Boron nitride - C04B 2237/365: Silicon carbide - C04B 2237/368: Silicon nitride - C04B 2237/38: Fiber or whisker reinforced - F05D 2300/222: Silicon - Y10T 29/4998: Combined manufacture including applying or shaping of fluent material - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - 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 - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component. ## Claims ### Claim 1 A method of forming pre-form ceramic matrix composite cavity for a ceramic matrix component comprising: providing a mandrel; applying a base ply to the mandrel; laying-up at least one CMC ply on the base ply; removing the mandrel; densifying the base ply and the at least one CMC ply; and wherein the remaining densified base ply and at least one CMC ply form the pre-form ceramic matrix component cavity having a desired geometry and a cavity formed therein. ### Claim 2 (depends on 1) The method of claim 1, including an additional step prior to the step of applying the base ply to the mandrel of aligning a tip member adjacent to the mandrel. ### Claim 3 (depends on 2) The method of claim 2, including an additional step after removing the mandrel of machining the tip member to remove additional material. ### Claim 4 (depends on 1) The method of claim 1, including an additional step after removing the mandrel of laying-up a first set of CMC plies in a lay-up tool and applying the pre-form ceramic matrix composite cavity to the first set of CMC plies in the lay-up tool. ### Claim 5 (depends on 4) The method of claim 4, including an additional step after the step of applying the pre-form ceramic matrix composite cavity of laying-up a second set of CMC plies to the pre-form ceramic matrix composite cavity. ### Claim 6 (depends on 5) The method of claim 5, including an additional step after laying-up the second set of CMC plies of processing the first set of CMC plies, the pre-form ceramic matrix composite cavity, and the second set of CMC plies in the lay-up tool to form the ceramic matrix composite component. ### Claim 7 (depends on 1) The method of claim 1, wherein the step of densifying includes melt infiltration or chemical vapor deposition. ### Claim 8 (depends on 1) The method of claim 1, wherein the step of removing the mandrel includes heat or chemical removal methods. ### Claim 9 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. ### Claim 10 (depends on 9) The pre-form ceramic matrix composite of claim 9, including a tip member in the cavity. ### Claim 11 (depends on 9) The pre-form ceramic matrix composite of claim 9, wherein the tip member is pre-formed. ### Claim 12 (depends on 9) The pre-from ceramic matrix composite of claim 9, wherein the ceramic matrix composite component is a turbine blade, turbine nozzle, turbine bucket, and combinations thereof. ### Claim 13 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. ### Claim 14 (depends on 13) The method of claim 13, wherein the ceramic matrix composite cavity includes a tip member. ### Claim 15 (depends on 13) The method of claim 13, including an additional step of after the step of densifying of inserting a tip member into the pre-from ceramic matrix composite cavity. ### Claim 16 (depends on 13) The method of claim 13, including an additional step after the step of densifying of machining the ceramic matrix composite to a desired geometry. ### Claim 17 (depends on 13) The method of claim 13, wherein the step of densifying includes melt infiltration or chemical vapor deposition. ### Claim 18 (depends on 13) The method of claim 13, including an additional step of after the step of applying the second base ply of autoclaving 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. ### Claim 19 (depends on 18) The method of claim 18, including an additional step of after the step of autoclaving of removing the tool. ### Claim 20 (depends on 19) The method of claim 19, including an additional step after the step of removing the tool of burn-out of 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.