Multi-layer ceramic composite porous structure

Abstract

An article of manufacture includes a first ceramic matrix composite (CMC) sheet having a number of flow passages therethrough, and a CMC foam layer bonded to the first CMC sheet. The CMC foam layer is an open-cell foam. The article of manufacture includes a second CMC sheet bonded to the CMC foam layer, the second CMC sheet having a thermal and environmental barrier coating and having a number of flow passages therethrough.

What is claimed is: 
     
         1 . A method, comprising:
 forming a first ceramic matrix composite (CMC) sheet, and providing a plurality of flow paths therethrough;   rigidizing the first CMC sheet into a component shape;   bonding a shaped, open-cell CMC foam layer to the first CMC sheet;   forming a second CMC sheet;   bonding the second CMC sheet to the foam layer thereby forming a component structure; and   curing the component structure.   
     
     
         2 . The method of  claim 1 , further comprising providing a plurality of flow paths through the second CMC sheet before the bonding the second CMC sheet. 
     
     
         3 . The method of  claim 2 , wherein providing the plurality of flow paths through the second CMC sheet comprises perforating the second CMC sheet. 
     
     
         4 . The method of  claim 3 , further comprising applying a thermal and environmental barrier coating to the second CMC sheet before the perforating. 
     
     
         5 . The method of  claim 1 , further comprising providing the plurality of flow paths through the first CMC sheet and the second CMC sheet by perforating the CMC sheets. 
     
     
         6 . The method of  claim 5 , further comprising staggering the perforations of the first CMC sheet and the second CMC sheet. 
     
     
         7 . The method of  claim 5 , further comprising aligning the perforations of the first CMC sheet and the second CMC sheet. 
     
     
         8 . The method of  claim 1 , further comprising:
 determining a component strength requirement;   in response to the component strength requirement, determining at least one design parameter selected from the parameters comprising: a number of layers each layer comprising a CMC foam layer interposed between two CMC sheets, a thickness of each of the CMC sheets, a density of the CMC foam layer, and a geometric shape of the component structure; and   conforming the component structure to the at least one design parameter.   
     
     
         9 . The method of  claim 1 , further comprising:
 determining a component cooling capability requirement;   in response to the component cooling capability requirement, determining at least one design parameter selected from the parameters comprising: a sizing of the flow paths, a shape factor of the flow paths, an alignment value of the flow paths, a thermal and environmental barrier coating design, and a density of the CMC foam layer; and   conforming the component structure to the at least one design parameter.   
     
     
         10 . A method, comprising:
 providing a multi-layer ceramic matrix composite (CMC) component comprising two opposing CMC sheets and a CMC open-cell foam layer therebetween;   exposing one of the CMC sheets directly to high-temperature turbine engine gases; and   flowing a coolant fluid through the CMC open-cell foam layer and through a plurality of flow passages defined by at least one of the CMC sheets.   
     
     
         11 . The method of  claim 10 , wherein the exposing comprises flowing turbine engine combustion gases in contact with the one of the CMC sheets. 
     
     
         12 . The method of  claim 11 , further comprising rotating the multi-layer CMC component during the exposing. 
     
     
         13 . The method of  claim 10 , wherein the flowing comprises providing a first heat transfer value from the multi-layer CMC component to the coolant fluid that is lower than a second heat transfer value, the second heat transfer value comprising a required heat transfer for a metal component. 
     
     
         14 . A method, comprising:
 forming a first ceramic matrix composite (CMC) sheet, and providing a plurality of flow paths therethrough;   rigidizing the first CMC sheet into a component shape;   bonding a shaped, open-cell CMC foam layer to the first CMC sheet;   forming a second CMC sheet;   providing a plurality of flow passages through the second CMC sheet;   bonding the second CMC sheet to the foam layer after the providing a plurality of flow passages step, thereby forming a component structure; and   curing the component structure.   
     
     
         15 . The method of  claim 14 , further comprising applying a thermal and environmental barrier coating to the second CMC sheet before the providing a plurality of flow passages step. 
     
     
         16 . The method of  claim 14 , further comprising providing the plurality of flow passages through the first CMC sheet prior the bonding a shaped, open-cell CMC foam layer to the first CMC sheet step. 
     
     
         17 . The method of  claim 16 , wherein the flow passages of the first CMC sheet are staggered relative to the flow passages of the second CMC sheet. 
     
     
         18 . The method of  claim 16 , wherein the flow passages of the first CMC sheet are aligned with the flow passages of the second CMC sheet. 
     
     
         19 . The method of  claim 14 , further comprising rigidizing the second CMC sheet prior to the providing a plurality of flow passages through the second CMC sheet step.