Method of forming a ceramic matrix composite component, a ceramic matrix composite component and a tip member

Abstract

A method of forming a ceramic matrix composite (CMC) component, a CMC component and a tip member are provided. The method of form the CMC component includes providing a component preform having a first end, a second end, and a cavity, the cavity having a pre-determined shape and a first engagement surface. The method includes forming a tip member from a pre-consolidated composite material, the tip member having a second engagement surface generally conforming to the first engagement surface. The method includes directing the second engagement surface to the first engagement surface. The method includes consolidating the component preform and tip member. The ceramic matrix composite component is formed having a desired geometry and the tip member stays in place in the cavity during operation of the ceramic matrix composite component.

What is claimed is: 
     
         1 . A method of forming a ceramic matrix composite component comprising:
 providing a component preform having a first end, a second end, and a cavity, the cavity having a pre-determined shape and a first engagement surface;   forming a tip member from a pre-consolidated composite material, the tip member having a second engagement surface generally conforming to the first engagement surface;   directing the second engagement surface to the first engagement surface; and   consolidating the component preform and tip member;   wherein the ceramic matrix composite component is formed having a desired geometry and the tip member stays in place in the cavity during operation of the ceramic matrix composite component.   
     
     
         2 . The method of  claim 1 , wherein the ceramic matrix composite component is a component selected from the group consisting of turbine blades, turbine nozzles, turbine buckets, and combinations thereof. 
     
     
         3 . The method of  claim 1 , wherein the pre-consolidated composite material comprises ceramic unidirectional plies, organic or inorganic based pre-preg plies, or organic or inorganic based cross-plies. 
     
     
         4 . The method of  claim 1 , wherein the pre-consolidated composite material has a thickness of about 0.254 millimeters to about 1 centimeter. 
     
     
         5 . The method of  claim 1 , wherein the step of forming includes cutting, laser cutting, waterjet cutting, and combinations thereof. 
     
     
         6 . The method of  claim 1 , wherein the first engagement surface includes a taper. 
     
     
         7 . The method of  claim 1 , wherein the taper of the first engagement surface forms a geometry that narrows toward an end of the cavity. 
     
     
         8 . The method of  claim 6 , wherein the second engagement surface includes a taper generally conforming to the taper of the first engagement surface. 
     
     
         9 . A ceramic matrix composite component comprising:
 a component preform having a first end, a second end, and a cavity, the cavity having a pre-determined shape and a first engagement surface;   a tip member formed from a pre-consolidated composite material, the tip member having a second engagement surface generally conforming to the first engagement surface; and   wherein the ceramic matrix composite component has a desired geometry and the tip member stays in place in the cavity during operation of the ceramic matrix composite component.   
     
     
         10 . The ceramic matrix composite of  claim 9 , wherein the ceramic matrix composite component is a component selected from the group consisting of turbine blades, turbine nozzles, turbine buckets, and combinations thereof. 
     
     
         11 . The ceramic matrix composite of  claim 9 , wherein the pre-consolidated composite material has a thickness of about 0.254 millimeters to about 6.35 millimeters. 
     
     
         12 . The ceramic matrix composite of  claim 9 , wherein the step of forming includes cutting, laser cutting, waterjet cutting, and combinations thereof. 
     
     
         13 . The ceramic matrix composite of  claim 9 , wherein the first engagement surface includes a taper. 
     
     
         14 . The ceramic matrix composite of  claim 13 , wherein the taper of the first engagement forms a geometry that narrows toward an end of the cavity. 
     
     
         15 . The ceramic matrix composite of  claim 9 , the second engagement surface of the tip member includes a taper generally conforming to the taper of the first engagement surface. 
     
     
         16 . A tip member for a cavity in a ceramic matrix composite component, the tip member formed from a pre-consolidated composite material, the tip member having a geometry that conforms to a pre-determined shape of a cavity and a second engagement surface that cooperates with a first engagement surface of the cavity of the ceramic matrix composite component. 
     
     
         17 . The tip member of  claim 16 , wherein the first engagement surface includes a taper. 
     
     
         18 . The tip member of  claim 16 , wherein the second engagement surface of the tip member includes a taper generally conforming to the taper of the first engagement surface.