Orthogonal weaving for complex shape preforms

Abstract

An orthogonal stitch-weave method and fiber architecture. The architecture allows near-net-shape composite preforms to be fabricated, thereby reducing costs associated with complex preform shapes and increasing desired strengths of the composite.

1 . A woven ceramic matrix composite preform for making a finished ceramic matrix composite shape comprising: 
 a predetermined number weft tows;    a predetermined number of stitcher tows; and    a predetermined number of warp tows;    wherein the weft tows, the stitcher tows and the warp tows are arranged in an orthogonal weave;    wherein the orthogonal weave forms a preform of a shape substantially the same as the shape of the finished ceramic matrix composite shape; and    wherein the weft tows, stitcher tows and the warp tows include a plurality of individual fibers comprising silicon carbide.    
   
   
       2 . (canceled)  
   
   
       3 . (canceled)  
   
   
       4 . The woven ceramic matrix composite preform of  claim 1 , wherein the preform shape is a shape requiring substantially no trimming prior to final fabrication into the final ceramic matrix composite.  
   
   
       5 . (canceled)  
   
   
       6 . The woven ceramic matrix composite preform of  claim 1 , wherein the stitcher tows are positioned in the preform shape in a configuration providing transverse fiber reinforcement.  
   
   
       7 . A woven ceramic matrix composite preform for making a finished ceramic matrix composite shape comprising: 
 a predetermined number weft tows;    a predetermined number of stitcher tows; and    a predetermined number of warp tows;    wherein the weft tows, the stitcher tows and the warp tows are arranged in an orthogonal weave;    wherein the orthogonal weave forms a preform of a shape substantially the same as the shape of the finished ceramic matrix composite shape; and    wherein the preform shape is an airfoil component for a gas turbine engine.    
   
   
       8 . The woven ceramic matrix composite preform of  claim 1 , wherein the weft tows, stitcher tows and the warp tows include a plurality of individual fibers.  
   
   
       9 . The woven ceramic matrix composite preform of  claim 1 , wherein the preform shape is a shape requiring substantially no trimming prior to final fabrication into the final ceramic matrix composite.  
   
   
       10 . The woven ceramic matrix composite preform of  claim 1 , wherein the stitcher tows are positioned in the preform shape in a configuration providing transverse fiber reinforcement.