Cmc shroud segment with interlocking mechanical joints and fabrication

Abstract

A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.

What is claimed is: 
     
         1 . A shroud segment comprising:
 a forward radial wall comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix;   an aft radial wall comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix;   at least one interlocking subcomponent comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix; and   an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent to form the shroud segment.   
     
     
         2 . The shroud segment of  claim 1 , wherein the at least one interlocking subcomponent comprises a flowpath cap comprised of a plurality of tabs cooperatively engaged with a plurality of openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         3 . The shroud segment of  claim 1 , wherein the at least one interlocking subcomponent comprises a forward overhang and an aft overhang each comprised of a plurality of tabs cooperatively engaged with a plurality of openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         4 . The shroud segment of  claim 1 , wherein the at least one interlocking subcomponent comprises a flowpath cap comprised of a plurality of tabs cooperatively engaged with a first plurality of openings formed in each of the forward radial wall and the aft radial wall and wherein the at least one interlocking subcomponent further comprises a forward overhang and an aft overhang comprised of a plurality of tabs cooperatively engaged with a second plurality of openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         5 . The shroud segment of  claim 1 , wherein the at least one interlocking subcomponent comprises an interlocking ceramic matrix composite (CMC) pin. 
     
     
         6 . The shroud segment of  claim 5 , wherein the at least one interlocking subcomponent further comprises a flowpath comprising a slot and wherein each of the forward radial wall and the aft radial wall comprise a cooperatively aligned slot, the interlocking CMC pin disposed therein each of the slots defining the interlocking mechanical joint. 
     
     
         7 . The shroud segment of  claim 1 , wherein the at least one interlocking subcomponent comprises a flowpath cap comprised of a plurality of tabs disposed in cooperative engagement with a plurality of dovetails of each of the forward radial wall and the aft radial wall. 
     
     
         8 . The shroud segment of  claim 1 , wherein the at least one interlocking subcomponent comprises a flowpath cap, a forward overhang and an aft overhang each comprised of a plurality of tabs and indents disposed in cooperative engagement with a plurality of dovetails of each of the forward radial wall and the aft radial wall. 
     
     
         9 . The shroud segment of  claim 8 , wherein the at least one interlocking subcomponent comprises a flowpath comprising a plurality of slots extending in a widthwise direction and having disposed therein a shaped pin, the shaped pin extending therethrough one or more openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         10 . The shroud segment of  claim 1 , wherein the at least one interlocking subcomponent comprises a flow path comprising a plurality of slots extending longitudinally a length of the flow path, and wherein each of the plurality of slots includes an obstruction extending from a surface of the slot and configured to cooperatively engage with a respective one of the forward radial wall and the aft radial well. 
     
     
         11 . The shroud segment of  claim 1 , wherein the shroud segment is a gas turbine engine component. 
     
     
         12 . A shroud segment for a gas turbine comprising:
 a forward radial wall comprised of a ceramic matrix composite (CMC) including a plurality of reinforcing fibers embedded in a matrix;   an aft radial wall comprised of a ceramic matrix composite (CMC) including a plurality of reinforcing fibers embedded in a matrix;   at least one interlocking subcomponent comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix; and   an interlocking mechanical joint joining each of the first radial wall and the aft radial wall to the at least one interlocking subcomponent to form the shroud segment,   wherein at least one or more of the forward radial wall, the aft radial wall, and the at least one interlocking subcomponent are bonded to at least another one of the forward radial wall, the aft radial wall, and the at least one interlocking subcomponent.   
     
     
         13 . The shroud segment of  claim 12 , wherein at least one interlocking subcomponent comprises a flowpath cap comprised of a plurality of tabs cooperatively engaged with a plurality of openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         14 . The shroud segment of  claim 12 , wherein the at least one interlocking subcomponent comprises a forward overhang and an aft overhang each comprised of a plurality of tabs cooperatively engaged with a plurality of openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         15 . The shroud segment of  claim 12 , wherein the at least one interlocking subcomponent comprises a flowpath cap comprised of a plurality of tabs cooperatively engaged with a first plurality of openings formed in each of the forward radial wall and the aft radial wall and a forward overhang and an aft overhang comprised of a plurality of tabs cooperatively engaged with a second plurality of openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         16 . The shroud segment of  claim 12 , wherein the at least one interlocking subcomponent comprises an interlocking ceramic matrix composite (CMC) pin. 
     
     
         17 . The shroud segment of  claim 16 , wherein the at least one interlocking subcomponent further comprises a flowpath comprised of a slot and wherein each of the forward radial wall and the aft radial wall comprise a cooperatively aligned slot, the interlocking CMC pin disposed therein each of the slots defining the interlocking mechanical joint. 
     
     
         18 . The shroud segment of  claim 12 , wherein the at least one interlocking subcomponent comprises a flowpath cap comprised of a plurality of tabs disposed in cooperative engagement with a plurality of dovetails of each of the forward radial wall and the aft radial wall. 
     
     
         19 . The shroud segment of  claim 12 , wherein the at least one interlocking subcomponent comprises a flowpath cap, a forward overhang and an aft overhang each comprised of a plurality of tabs and indents disposed in cooperative engagement with a plurality of dovetails of each of the forward radial wall and the aft radial wall. 
     
     
         20 . The shroud segment of  claim 19 , wherein the at least one interlocking subcomponent comprises a flowpath comprising a plurality of slots extending in a widthwise direction and having disposed therein a shaped pin, the shaped pin extending therethrough one or more openings formed in each of the forward radial wall and the aft radial wall. 
     
     
         21 . The shroud segment of  claim 12 , wherein the at least one interlocking subcomponent comprises a flow path comprising a plurality of slots extending longitudinally a length of the flow path, and wherein each of the plurality of slots includes an obstruction extending from a surface of the slot and configured to cooperatively engage with a respective one of the forward radial wall and the aft radial well. 
     
     
         22 . A method of forming a ceramic matrix composite (CMC) component comprising:
 providing a forward radial wall comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix;   providing an aft radial wall comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix;   providing at least one interlocking subcomponent comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix; and   mechanically joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent at an interlocking mechanical joint to form the shroud segment.   
     
     
         23 . The method of  claim 22 , wherein at least one interlocking subcomponent comprises one of:
 a flowpath cap comprised of a plurality of tabs cooperatively engaged with a plurality of openings formed in each of the forward radial wall and the aft radial wall;   a forward overhang and an aft overhang each comprised of a plurality of tabs cooperatively engaged with a plurality of openings formed in each of the forward radial wall and the aft radial wall;   a flowpath cap comprised of a plurality of tabs cooperatively engaged with a first plurality of openings formed in each of the forward radial wall and the aft radial wall and a forward overhang and an aft overhang comprised of a plurality of tabs cooperatively engaged with a second plurality of openings formed in each of the forward radial wall and the aft radial wall;   a flowpath comprised of a slot and wherein each of the forward radial wall and the aft radial wall comprise a cooperatively aligned slot, an interlocking CMC pin disposed therein each of the slots defining the interlocking mechanical joint;   a flowpath cap comprised of a plurality of tabs disposed in cooperative engagement with a plurality of dovetails of each of the forward radial wall and the aft radial wall;   a flowpath cap, a forward overhang and an aft overhang each comprised of a plurality of tabs and indents disposed in cooperative engagement with a plurality of dovetails of each of the forward radial wall and the aft radial wall;   a flowpath comprising a plurality of slots extending in a widthwise direction and having disposed therein a shaped pin, the shaped pin extending therethrough one or more openings formed in each of the forward radial wall and the aft radial wall; and   a flow path comprising a plurality of slots extending longitudinally a length of the flow path, and wherein each of the plurality of slots includes an obstruction extending from a surface of the slot and configured to cooperatively engage with a respective one of the forward radial wall and the aft radial well.