# US 9,751,807 B2 · Consumable core for manufacture of composite articles and related method

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- Number: US 9,751,807 B2
- Document ID: US9751807B2
- Status: Granted
- Kind: B2
- Application number: 13/586,930
- Filed: 2012-08-16
- Published: 2014-02-20
- Granted: 2017-09-05
- Earliest claimed: 2012-08-16
- Assignees: General Electric Company
- Applicants: Glenn Curtis Taxacher; Peter de Diego; Paul Edward Gray; Philip Harold Monaghan
- Inventors: Glenn Curtis Taxacher; Peter de Diego; Paul Edward Gray; Philip Harold Monaghan
- Web page: https://patentgrep.com/patent/US9751807B2

## CPC

- C04B 35/5607: {based on refractory metal carbides}
- C04B 35/563: based on boron carbide
- C04B 35/573: obtained by reaction sintering {or recrystallisation}
- C04B 35/653: Processes involving a melting step
- C04B 2235/404: Refractory metals
- C04B 2235/421: Boron
- C04B 2235/428: Silicon
- C04B 2235/616: Liquid infiltration of green bodies or pre-forms
- 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

## Abstract

Systems, methods and devices adapted to ease manufacture of composite articles (e.g., ceramic composite articles), particularly composite articles which include a hollow feature are disclosed. In one embodiment, a system includes: a consumable core formed to be disposed within an inner portion of a composite precursor, the consumable core adapted to convert into an infiltrant during a manufacturing process and infiltrate the composite precursor.

## Claims

### Claim 1

A system comprising:
a consumable core configured to be disposed within a hollow feature within a composite precursor, the consumable core completely enclosed by the composite precursor, the consumable core configured to be consumed during a melt infiltration manufacturing process, wherein the consumable core infiltrates the composite precursor, wherein the hollow feature is vacated by the consumable core.

### Claim 2 (depends on 1)

The system of claim 1, further comprising an external feed connected to the consumable core via a wick for supplying a flow of infiltrant material to the composite precursor.

### Claim 3 (depends on 1)

The system of claim 1, wherein the consumable core includes a cast material.

### Claim 4 (depends on 1)

The system of claim 1, wherein the consumable core includes at least one of silicon or boron.

### Claim 5 (depends on 1)

The system of claim 1, further comprising an external block disposed proximate the composite precursor for supplying infiltrant material to the composite precursor.

### Claim 6

A system, comprising:
a composite precursor having a hollow feature; and
a consumable core disposed within the hollow feature of the composite precursor, the consumable core completely enclosed by the composite precursor, the consumable core configured to convert into an infiltrant during a manufacturing process and infiltrate the composite precursor wherein the hollow feature is vacated during the melt infiltration manufacturing process.

### Claim 7 (depends on 6)

The system of claim 6, further comprising an external block disposed substantially proximate the composite precursor and adapted to supply additional infiltrant material to infiltrate the composite precursor.

### Claim 8 (depends on 6)

The system of claim 6, further comprising a reservoir connected to the consumable core via a drain, the reservoir adapted to receive a flow of infiltrant material from the consumable core.

### Claim 9 (depends on 6)

The system of claim 6, wherein the consumable core is formed from sintered powders and includes at least one of silicon and boron.

### Claim 10 (depends on 6)

The system of claim 6 further comprising:
an external feed connected to the consumable core via a wick, the external feed adapted to supply a flow of infiltrant material to the composite precursor.

### Claim 11 (depends on 6)

The system of claim 6, wherein the composite precursor is porous and carbonized.

### Claim 12 (depends on 10)

The system of claim 10, wherein the wick includes woven carbon fiber.