Ceramic matrix composite (cmc) component resistant to edge cracks

A method of forming a ceramic matrix composite (CMC) component, the method comprising:

• stacking a plurality of CMC plies having, at least, a first CMC ply and a second CMC ply together to form a laminate structure, the first CMC ply being formed from a CMC material reinforced with a fiber material having a first fiber orientation, the second CMC ply being formed from the CMC material reinforced with the fiber material having a second fiber orientation, the first and second fiber orientations being arranged in a cross-ply pattern in a plane of in the laminate structure, the laminate structure comprising at least one edge;
• arranging at least one end cap ply to cover at least a portion of the at least one edge of the laminate structure, the at least one end cap ply being formed of the CMC material reinforced with the fiber material having a third fiber orientation, at least a portion of a plane of the at least one end cap ply being perpendicular to the plane of the laminate structure;
• and
• processing the laminate structure to form the CMC component.

A method of upgrading or repairing a ceramic matrix composite (CMC) component, the method comprising:

• arranging a plurality of CMC plies having, at least, a first CMC ply and a second CMC ply together to form a laminate structure, the first CMC ply being formed from a CMC material reinforced with a fiber material having a first fiber orientation, the second CMC ply being formed from the CMC material reinforced with the fiber material having a second fiber orientation, the first and second fiber orientations being arranged in a cross-ply pattern in a plane of the laminate structure, the laminate structure comprising at least one edge;
• arranging at least one end cap ply to cover at least a portion of the at least one edge of the CMC component, the at least one end cap ply being formed of the CMC material reinforced with the fiber material having a third fiber orientation, at least a portion of a plane of the at least one end cap ply being perpendicular to the plane of the laminate structure;
• and
• processing the laminate structure to form the CMC component.