Method for making stiffened ceramic matrix composite panel
AssigneeCorning Incorporated
InventorsRoger A. Allaire, Thomas P. Grandi, Victor F. Janas
Life of this patent
Estimating the term…
Abstract
An improved method for the fabrication of lightweight ceramic matrix composite panels, utilizing pressure forming with floating tooling to shape integral stiffeners such as raised integral surface channels on panel surfaces. The consolidation of green composite material against refractory floating tools by hot hydrostatic or isostatic (gas) pressing, followed by removal of the tooling, yields a strong, rigid, yet lightweight ceramic structure.
Claims15
A method for the manufacture of a ceramic matrix composite panel incorporating an integral composite support member which comprises the steps of:
- providing composite material for a panel preform and a support preform, the material being comprised of green ceramic sheet formed of inorganic fibers pre-impregnated with powdered glass:
- providing a floating refractory forming tool, the tool comprising a shaping surface configured for shaping green ceramic sheet into an integral support member of a selected support configuration;
- combining the panel preform, support preform and floating tool into an assembly wherein at least a portion of the support preform is in contact with the surface of the panel preform, and wherein the shaping surface of the floating tool is in contact with and supports the support preform in approximately said selected support configuration;
- fastening the support preform to the panel preform at points adjacent to the floating tool to conform the preforms more closely to the floating tool;
- heating the assembly to a temperature at least sufficient to soften the powdered glass while applying pressure to the assembly, the pressure being at least sufficient to fuse the support preform to the panel preform, to shape the support preform against the floating tool into an integral support member of the selected support configuration, and to consolidate the fused panel preform and support preform into a dense ceramic composite structure comprising a panel with an integral support member, and
- removing the floating tool from the ceramic composite structure.
A method for the manufacture of a ceramic matrix composite panel incorporating an integral channeled support on the panel surface which comprises the steps of:
- providing material for a panel preform and support preform, the material comprising green ceramic sheet formed of inorganic fibers pre-impregnated with powdered glass;
- providing a refractory floating tool having a cross-sectional shape selected to correspond to a bore shape for the integral channeled support;
- positioning the panel preform on a rigid refractory panel former;
- positioning the refractory floating tool on the panel preform at a location selected for additional panel support;
- overlaying the floating tool and at least immediately adjoining portions of the panel preform with the support preform, thus to provide an assembly of the panel preform, forming tool, and support preform;
- fastening the support preform to the panel preform at points adjacent to the floating tool, thus to conform the support preform more closely to the bore shape;
- heating the assembly at a temperature at least sufficient to soften the powdered glass while applying isostatic pressure to the assembly, the isostatic pressure being at least sufficient to fuse the support preform to the panel preform, to shape the support preform around the floating tool, and to consolidate the fused panel and channeled support into a dense ceramic composite panel;
- and
- removing the forming tool form the channeled support structure.
Dependencies are inferred from the claim text.