# US 2025/0027414 A1 · Composite Component Modifications

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- Number: US 2025/0027414 A1
- Document ID: US20250027414A1
- Status: Published application
- Kind: A1
- Application number: 18/906,542
- Filed: 2024-10-04
- Published: 2025-01-23
- Earliest claimed: 2018-06-08
- Assignees: General Electric Company
- Applicants: General Electric Company
- Inventors: Herbert Chidsey Roberts; Glenn Curtis Taxacher; Timothy P. Coons; Jared Hogg Weaver; Daniel Gene Dunn; Jerome Geoffrey Magnant
- Web page: https://patentgrep.com/patent/US20250027414A1

## CPC

- C04B 37/00: Joining burned ceramic articles with other burned ceramic articles or other articles by heating {(soldering and welding materials B23K35/24; laminated products B32B, E04C)}
- F01D 5/005: {Repairing methods or devices}
- B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products
- C04B 37/001: {directly with other burned ceramic articles}
- C04B 41/459: {Temporary coatings or impregnations (C04B40/04 takes precedence)}
- C04B 41/81: Coating or impregnation
- F01D 25/005: {Selecting particular materials}
- C04B 2235/5224: Alumina or aluminates
- C04B 2235/5228: Silica and alumina, including aluminosilicates, e.g. mullite
- C04B 2235/5244: Silicon carbide
- C04B 2235/5248: Carbon, e.g. graphite
- C04B 2235/5252: having a specific pre-form
- C04B 2235/5256: Two-dimensional, e.g. woven structures
- C04B 2235/5268: Orientation of the fibers
- C04B 2235/616: Liquid infiltration of green bodies or pre-forms
- C04B 2237/341: Silica or silicates
- C04B 2237/343: Alumina or aluminates
- C04B 2237/365: Silicon carbide
- C04B 2237/38: Fiber or whisker reinforced
- C04B 2237/385: Carbon or carbon composite
- C04B 2237/52: Pre-treatment of the joining surfaces, e.g. cleaning, machining
- C04B 2237/58: Forming a gradient in composition or in properties across the laminate or the joined articles
- C04B 2237/61: Joining two substrates of which at least one is porous by infiltrating the porous substrate with a liquid, such as a molten metal, causing bonding of the two substrates, e.g. joining two porous carbon substrates by infiltrating with molten silicon
- F05D 2220/32: in gas turbines
- F05D 2230/80: Repairing, retrofitting or upgrading methods
- F05D 2240/11: Shroud seal segments
- F05D 2240/12: Fluid guiding means, e.g. vanes
- F05D 2240/128: Nozzles
- F05D 2240/14: Casings or housings protecting or supporting assemblies within
- F05D 2240/30: Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
- F05D 2240/35: Combustors or associated equipment
- 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
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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

Composite components and methods for adding a composite material to a composite component are provided. For example, a method comprises positioning a composite material segment against the composite component to form a component layup; applying an insulating material around at least a portion of the component layup to form an insulated layup; and densifying the insulated layup, where the composite component was previously densified before positioning the composite material segment against the composite component. In some embodiments, the composite material is ceramic matrix composite (CMC) and the composite material segment is a plurality of CMC plies. The composite component may be a CMC gas turbine engine component that comprises an original CMC component and a new CMC material segment joined to the original CMC component through the transfer of silicon between the original CMC component and the new CMC material segment during melt infiltration.

## Claims

### Claim 1

A ceramic matrix composite (CMC) gas turbine engine component, comprising:
an original CMC component; and
a new CMC material segment joined to the original CMC component through a transfer of silicon between the original CMC component and the new CMC material segment during melt infiltration,
wherein a source of silicon is applied to the original CMC component during melt infiltration to minimize porosity in the original CMC component through a loss of silicon from the original CMC component.

### Claim 2 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the CMC gas turbine engine component is selected from the group consisting of: a blade, a vane, a nozzle, a shroud, a combustor liner, and a center frame.

### Claim 3 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the source of silicon is a silicon-based insulating material comprising, by dry weight, 25-95% silicon and 0-50% boron nitride.

### Claim 4 (depends on 3)

The CMC gas turbine engine component of claim 3, wherein the silicon-based insulating material further comprises, by dry weight, 0-20% organic binder.

### Claim 5 (depends on 3)

The CMC gas turbine engine component of claim 3, wherein the silicon-based insulating material further comprises, by dry weight, 0-10% boron carbide.

### Claim 6 (depends on 1)

The CMC gas turbine engine component of claim 1, further comprising a coating disposed on one or more surfaces of the original CMC component.

### Claim 7 (depends on 6)

The CMC gas turbine engine component of claim 6, wherein the coating is a non-organic parting agent capable of withstanding a temperature of at least 1000° C.

### Claim 8 (depends on 7)

The CMC gas turbine engine component of claim 7, wherein the coating is boron nitride.

### Claim 9 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the original CMC component includes a damaged area, and the new CMC material segment is disposed on the damaged area.

### Claim 10 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the new CMC material segment includes a plurality of CMC plies, wherein an orientation of the plurality of CMC plies is varied such that fibers of at least one ply of the plurality of CMC plies are oriented in a different direction to fibers of at least one other ply of the plurality of CMC plies.

### Claim 11 (depends on 10)

The CMC gas turbine engine component of claim 10, wherein the plurality of CMC plies include a first CMC ply and a second CMC ply disposed on the first CMC ply, wherein fibers of the first CMC ply extend in a longitudinal direction, and wherein fibers of the second CMC ply extend 90 degrees away the longitudinal direction.

### Claim 12 (depends on 11)

The CMC gas turbine engine component of claim 11, wherein the plurality of CMC plies include a first CMC ply and a second CMC ply disposed on the first CMC ply, wherein fibers of the first CMC ply extend-45 degrees relative to a longitudinal direction, and wherein fibers of the second CMC ply extend 45 degrees relative to the longitudinal direction.

### Claim 13 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the source of silicon produces a high silicon vapor pressure at an outer surface of the original CMC component during the melt infiltration.

### Claim 14 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the source of silicon impedes oxidation of the original CMC component.

### Claim 15 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the source of silicon is a silicon-based insulating material having a thickness in a range from 0.5 mm to 35 mm.

### Claim 16 (depends on 15)

The CMC gas turbine engine component of claim 15, wherein the silicon-based insulating material has a thickness in a range from 2 mm to 15 mm.

### Claim 17 (depends on 15)

The CMC gas turbine engine component of claim 15, wherein the silicon-based insulating material is a slurry.

### Claim 18 (depends on 1)

The CMC gas turbine engine component of claim 1, wherein the new CMC material segment is a tape of CMC plies.

### Claim 19

An insulated component layup for forming a ceramic matrix composite (CMC) gas turbine engine component, the insulated component layup comprising:
a previously densified CMC component;
a CMC material segment positioned against the previously densified CMC component to form component layup; and
a silicon-based insulating material applied, without bonding, against at least a portion of previously densified outer surfaces of the component layup.

### Claim 20 (depends on 19)

The insulated component layup of claim 19, wherein the silicon-based insulating material is configured to be removed after densifying the insulated component layup.