Hybrid ceramic matrix composite turbine blades for improved processibility and performance

Abstract

The present invention is a hybrid ceramic matrix composite turbine engine component comprising an outer shell section(s) and an inner core section(s), wherein the outer shell section(s) and the inner core section(s) were bonded together using an MI process. The outer shell section(s) comprises a SiC/SiC material that has been manufactured using a process selected from the group consisting of a slurry cast MI process and a prepreg MI process. The inner core section(s) comprises a material selected from the group consisting an Si/SiC composite material and a monolithic ceramic material. The Si/SiC composite material may be manufactured using the Silcomp process. The present invention may be a high pressure turbine blade, a high pressure turbine vane, a low pressure turbine blade, or a low pressure turbine vane. The present invention is also a method of manufacturing a hybrid ceramic matrix composite turbine engine component.

1 . A ceramic matrix composite turbine engine component comprising: 
 a core insert section comprising a material selected from the group consisting of a silicon-silicon carbide composite and a monolithic ceramic; and    an outer shell section comprising a silicon carbide-silicon carbide composite material, wherein the at least one outer shell section and the at least one core insert section are bonded together using a silicon melt infiltration process.    
   
   
       2 . The turbine engine component of  claim 1 , wherein the component comprises a plurality of outer shell sections.  
   
   
       3 . The turbine engine component of  claim 1 , wherein the component comprises a plurality of core insert sections and a plurality of outer shell sections.  
   
   
       4 . The turbine engine component of  claim 1 , wherein the core insert section is a silicon-silicon carbide composite.  
   
   
       5 . The turbine engine component of  claim 4 , wherein the core insert section is manufactured using a Silcomp process.  
   
   
       6 . The turbine engine component of  claim 1 , wherein the core insert section is a monolithic ceramic material.  
   
   
       7 . The turbine engine component of  2 , wherein the outer shell section is silicon carbide-silicon carbide composite material.  
   
   
       8 . The turbine engine component of  claim 7 , wherein the outer shell section is manufactured using a slurry cast melt infiltration process.  
   
   
       9 . The turbine engine component of  claim 7 , wherein the outer shell section is manufactured using a prepreg melt infiltration process.  
   
   
       10 . The turbine engine component of  claim 1 , wherein the component is a turbine vane.  
   
   
       11 . The turbine engine component of  claim 1 , wherein the component is a turbine nozzle.  
   
   
       12 . A method of manufacturing a ceramic matrix composite turbine blade comprising the steps of: 
 providing a core insert section having a preselected geometry, the core insert section comprising a material selected from the group consisting of silicon carbide-silicon carbide composite preform having at least some porosity, silicon-silicon carbide composite, silicon-silicon carbide composite preform having at least some porosity, silicon-silicon carbide composite, and a monolithic ceramic;    providing a plurality of plies of silicon carbide prepreg cloth;    laying up a preselected number of silicon carbide prepreg plies to form an outer shell section;    assembling the core insert section and the outer shell section into a turbine blade form, the turbine blade form comprising a dovetail section and an airfoil section, wherein the core insert section is positioned in the dovetail section of the turbine blade form;    autoclaving the turbine blade form;    filling remaining porosity in the turbine blade form with at least silicon using a silicon melt infiltration process, the filling also forming a bond between the core insert section and the outer shell preform.    
   
   
       13 . The method of  claim 12 , wherein the core insert section is a silicon-silicon carbide preform.  
   
   
       14 . The method of  claim 13 , wherein the silicon-silicon carbide preform includes carbon microspheres.  
   
   
       15 . The method of  claim 12 , wherein the core insert section is a silicon carbide-silicon carbide preform manufactured using a slurry cast process.  
   
   
       16 . The method of  claim 12 , wherein the core insert section is a silicon carbide-silicon carbide preform manufactured using a prepreg process.  
   
   
       17 . A method of manufacturing a ceramic matrix composite turbine blade comprising the steps of: 
 providing a core insert section having a preselected geometry, the core insert section comprising a material selected from the group consisting of a silicon carbide-silicon carbide composite preform having at least some porosity, a silicon-silicon carbide composite, the silicon-silicon carbide composite preform having at least some porosity, a silicon-silicon carbide composite, and a monolithic ceramic;    providing an outer shell section preform, the outer shell preform having at least some porosity;    assembling the core insert section and the outer shell preform into a turbine blade form, the turbine blade form comprising a dovetail section and an airfoil section, wherein the core insert section is positioned in the dovetail section of the turbine blade form; and    filling remaining porosity in the turbine blade forms with at least silicon using the silicon melt infiltration process, the filling also forming a bond between the at least one core insert section and the at least one outer shell preform.    
   
   
       18 . The method of  claim 17 , wherein the core insert section is a silicon-silicon carbide preform.  
   
   
       19 . The method of  claim 18 , wherein the silicon-silicon carbide preform includes carbon micro spheres.  
   
   
       20 . The method of  claim 19 , wherein the core insert section is a silicon carbide-silicon carbide preform manufactured using a slurry cast process.