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1. 发明授权

US07968031B2 Ceramic composite with integrated compliance/wear layer 有权
标题翻译：陶瓷复合材料具有一体化/耐磨层
公开(公告)号：US07968031B2
公开(公告)日：2011-06-28
申请号：US11938349
申请日：2007-11-12
申请人： Douglas Melton Carper , Suresh Sabramanian
发明人： Douglas Melton Carper , Suresh Sabramanian
IPC分类号： B23P15/00
CPC分类号： C04B35/62863 , C04B35/565 , C04B35/573 , C04B35/58 , C04B35/58092 , C04B35/583 , C04B35/62868 , C04B35/62871 , C04B35/62884 , C04B35/62894 , C04B35/806 , C04B2235/3826 , C04B2235/386 , C04B2235/3873 , C04B2235/404 , C04B2235/421 , C04B2235/428 , C04B2235/5244 , C04B2235/5256 , C04B2235/75 , C04B2235/80 , F01D5/282 , F01D5/284 , F01D5/3092 , F05D2300/222 , F05D2300/2261 , Y02T50/672 , Y10T29/49236
摘要： The integral layer provides a ductile interface for attachment locations of a turbine engine component where a metallic surface is adjacent the attachment location. The ductile layer provides a favorable load distribution through the composite at the attachment location, and eliminates the need for a metallic shim.
摘要翻译：整体层为涡轮发动机部件的附接位置提供延性界面，其中金属表面邻近附接位置。韧性层通过复合材料在附着位置提供有利的载荷分布，并且不需要金属垫片。

2. 发明申请

US20080124512A1 CMC ARTICLES HAVING SMALL COMPLEX FEATURES 有权
标题翻译：具有小复杂特征的CMC文章
公开(公告)号：US20080124512A1
公开(公告)日：2008-05-29
申请号：US11563747
申请日：2006-11-28
申请人： James Dale Steibel , Douglas Melton Carper , Suresh Subramanian , Stephen Mark Whiteker
发明人： James Dale Steibel , Douglas Melton Carper , Suresh Subramanian , Stephen Mark Whiteker
IPC分类号： B32B18/00 , B32B5/00
CPC分类号： F01D5/147 , B32B18/00 , C04B35/573 , C04B35/62227 , C04B35/62863 , C04B35/62868 , C04B35/62871 , C04B35/80 , C04B35/806 , C04B2235/5252 , C04B2235/526 , C04B2235/5268 , C04B2235/602 , C04B2235/6028 , C04B2235/604 , F01D5/282 , F01D5/284 , F05C2203/0839 , F05D2300/21 , F05D2300/2261 , F05D2300/2283 , F05D2300/44 , F05D2300/603 , F05D2300/6034 , F05D2300/614 , Y02T50/67 , Y02T50/672 , Y10T156/10 , Y10T428/24058 , Y10T428/24124 , Y10T428/249929
摘要： A ceramic matrix composite (CMC) component for gas turbine engines, the component having fine features such as thin edges with thicknesses of less than about 0.030 inches and small radii of less that about 0.030 inches formed using the combination of prepreg plies layed up with non-ply ceramic inserts. The CMC components of the present invention replace small ply inserts cut to size to fit into areas of contour change or thickness change, and replace the small ply inserts with a fabricated single piece discontinuously reinforced composite insert, resulting in fewer defects, such as wrinkles, and better dimensional control.
摘要翻译：用于燃气涡轮发动机的陶瓷基体复合材料（CMC）组件，该组件具有细小的特征，例如厚度小于约0.030英寸的薄边缘和小于约0.030英寸的小半径，使用非预制片 - 陶瓷插件。本发明的CMC部件代替切割成尺寸的小层嵌入件以适应轮廓变化或厚度变化的区域，并且用制造的单件不连续增强的复合材料插入件代替小层嵌入物，导致更少的缺陷，例如皱纹，和更好的尺寸控制。

3. 发明授权

US07247212B2 Orthogonal weaving for complex shape preforms 有权
标题翻译：用于复杂形状预制件的正交织造
公开(公告)号：US07247212B2
公开(公告)日：2007-07-24
申请号：US11018221
申请日：2004-12-21
申请人： Timothy Daniel Kostar , Douglas Melton Carper , Suresh Subramanian
发明人： Timothy Daniel Kostar , Douglas Melton Carper , Suresh Subramanian
IPC分类号： C04B35/80 , D03D23/00 , D03D1/00 , F02C7/00 , F01D5/28
CPC分类号： C04B35/83 , B28B19/00 , C04B35/573 , C04B2235/5224 , C04B2235/5228 , C04B2235/5244 , C04B2235/5256 , D03D25/005 , D03D41/004 , Y10T442/3195
摘要： 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.
摘要翻译：正交缝编织法和纤维架构。该结构允许制造近净形复合预成型件，从而降低与复合预成型件形状相关联的成本并增加复合材料的期望强度。

4. 发明授权

US07223465B2 SiC/SiC composites incorporating uncoated fibers to improve interlaminar strength 有权
标题翻译： SiC / SiC复合材料包含未涂覆的纤维，以提高层间强度
公开(公告)号：US07223465B2
公开(公告)日：2007-05-29
申请号：US11025510
申请日：2004-12-29
申请人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper
发明人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper
IPC分类号： B32B17/12 , B32B15/04 , B32B11/00 , C04B35/00
CPC分类号： C04B35/573 , C04B35/565 , C04B35/62868 , C04B35/62871 , C04B35/62873 , C04B35/62884 , C04B35/62894 , C04B35/62897 , C04B35/806 , C04B2235/421 , C04B2235/524 , C04B2235/5244 , F01D5/282 , F01D5/284 , F05D2300/2261 , F05D2300/614 , F05D2300/702 , Y02T50/67 , Y02T50/672 , Y10T428/249928 , Y10T428/249929 , Y10T428/249931 , Y10T428/30 , Y10T442/2975
摘要： The present invention is a ceramic matrix composite turbine engine component, wherein the component has a region of expected higher interlaminate stress during normal engine operation. The component includes both coated fiber tows and uncoated fiber tows arranged together into a preselected form, wherein the uncoated fiber tows are located at predetermined regions of expected high interlaminate stress. The invention further includes method of manufacturing a CMC such as a composite turbine engine component, wherein the component has a region of expected higher interlaminate stress during engine operation.
摘要翻译：本发明是一种陶瓷基体复合涡轮发动机部件，其中该部件在正常的发动机运转期间具有期望的较高的层间应力的区域。该组件包括一起布置成预选形式的涂覆的纤维束和未涂覆的纤维束，其中未涂覆的纤维束位于预期的高层间应力的预定区域。本发明还包括制造诸如复合涡轮发动机部件的CMC的方法，其中所述部件在发动机操作期间具有期望的较高的层间应力的区域。

5. 发明授权

US07597838B2 Functionally gradient SiC/SiC ceramic matrix composites with tailored properties for turbine engine applications 有权
标题翻译：功能梯度SiC / SiC陶瓷基体复合材料，适用于涡轮发动机应用
公开(公告)号：US07597838B2
公开(公告)日：2009-10-06
申请号：US11027403
申请日：2004-12-30
申请人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper , Toby George Darkins, Jr.
发明人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper , Toby George Darkins, Jr.
IPC分类号： B32B17/12 , B32B15/04 , C04B35/00 , C04B33/34 , C04B35/64
CPC分类号： C04B35/806 , C04B35/565 , C04B35/62863 , C04B35/62865 , C04B35/62868 , C04B35/62871 , C04B35/62873 , C04B35/62884 , C04B35/62894 , C04B35/62897 , C04B2235/522 , C04B2235/5224 , C04B2235/5232 , C04B2235/524 , C04B2235/5244 , C04B2235/5248 , C04B2235/5264 , C04B2235/80 , F01D5/282 , F01D5/284 , F05C2203/0839 , F05D2300/2261 , F05D2300/2283 , F05D2300/603 , Y02T50/672 , Y10T428/2495 , Y10T428/24975 , Y10T428/249924 , Y10T428/249928 , Y10T428/249929 , Y10T428/24993 , Y10T428/249931 , Y10T428/249939 , Y10T428/24994 , Y10T428/249941 , Y10T428/265 , Y10T442/2975
摘要： A ceramic matrix composite with a ceramic matrix and a gradient layering of coating on ceramic fibers. The coating typically improves the performance of the composite in one direction while degrading it in another direction. For a SiC-SiC ceramic matrix composite, a BN coating is layered in a gradient fashion or in a step-wise fashion in different regions of the article comprising the ceramic. The BN coating thickness is applied over the ceramic fibers to produce varying desired physical properties by varying the coating thickness within differing regions of the composite, thereby tailoring the strength of the composite in the different regions. The coating may be applied as a single layer as a multi-layer coating to enhance the performance of the coating as the ceramic matrix is formed or infiltrated from precursor materials into a preform of the ceramic fibers.
摘要翻译：陶瓷基复合陶瓷基体和陶瓷纤维上涂层的梯度分层。涂层通常在一个方向上改善复合材料的性能，同时使其在另一方向上降解。对于SiC-SiC陶瓷基质复合材料，在包含陶瓷的制品的不同区域中，以梯度或逐步的方式层叠BN涂层。通过改变复合材料的不同区域内的涂层厚度，在陶瓷纤维上施加BN涂层厚度以产生变化的所需物理性能，由此调整复合材料在不同区域中的强度。作为多层涂层，可以将涂层作为单层施加，以在陶瓷基体由前体材料形成或从陶瓷纤维的预成型体中渗透时提高涂层的性能。

6. 发明授权

US07579094B2 Use of biased fabric to improve properties of SiC/SiC ceramic composites for turbine engine components 有权
标题翻译：使用偏置织物来改善涡轮发动机部件的SiC / SiC陶瓷复合材料的性能
公开(公告)号：US07579094B2
公开(公告)日：2009-08-25
申请号：US11424722
申请日：2006-06-16
申请人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper , Brian Keith Flandermeyer
发明人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper , Brian Keith Flandermeyer
IPC分类号： B32B9/00
CPC分类号： F01D5/282 , F01D5/284 , F05C2203/0839 , F05D2300/2261 , F05D2300/6012 , Y02T50/67 , Y02T50/672 , Y10T428/30
摘要： The present invention is a ceramic matrix composite turbine engine component, wherein the component has a direction of maximum tensile stress during normal engine operation. The component comprises a plurality of biased ceramic plies, wherein each biased ply comprises ceramic fiber tows, the tows being woven in a first warp direction and a second weft direction, the second weft direction lying at a preselected angular orientation with respect to the first warp direction, wherein a greater number of tows are woven in the first warp direction than in the second weft direction, and wherein a number of tows in the second weft direction allows the biased plies to maintain their structural integrity when handled. The plurality of biased plies are laid up in a preselected arrangement to form the component, and a preselected number of the plurality of biased plies are oriented such that the orientation of the first warp direction of the preselected number of biased plies lie about in the direction of maximum tensile stress during normal engine operation. A coating is applied to the plurality of biased plies. The coating is selected from the group consisting of BN, SiC, and combinations thereof. A ceramic matrix material lies in interstitial regions between the tows of each biased ply and the interstitial region between the biased plies.
摘要翻译：本发明是一种陶瓷基体复合涡轮发动机部件，其中该部件在正常发动机运转期间具有最大拉伸应力的方向。所述组件包括多个偏置的陶瓷层，其中每个偏置层包括陶瓷纤维丝束，所述丝束以第一经向和第二纬向织造，所述第二纬向相对于所述第一翘曲位于预选角度取向方向，其中在第一经向方向上比在第二纬向上编织更多数量的丝束，并且其中在第二纬向方向上的多个丝束允许偏置层在处理时保持其结构完整性。多个偏置层叠被布置成预选的布置以形成部件，并且多个偏置层的预选数量被定向成使得预选数量的偏置层片的第一经向方向的取向位于方向在正常发动机运行期间最大拉伸应力。将涂层施加到多个偏压层。涂层选自BN，SiC及其组合。陶瓷基质材料位于每个偏置层的丝束之间的间隙区域和偏置层之间的间隙区域之间。

7. 发明申请

US20080132398A1 PROCESS OF PRODUCING A COMPOSITE COMPONENT AND INTERMEDIATE PRODUCT THEREOF 有权
标题翻译：生产复合组件的方法及其中间产品
公开(公告)号：US20080132398A1
公开(公告)日：2008-06-05
申请号：US11566370
申请日：2006-12-04
申请人： Timothy Daniel Kostar , Douglas Melton Carper , Suresh Subramanian , James Dale Steibel
发明人： Timothy Daniel Kostar , Douglas Melton Carper , Suresh Subramanian , James Dale Steibel
IPC分类号： C04B35/00 , B29C44/04
CPC分类号： D03D15/00 , C04B35/80 , C04B2235/5244 , C04B2235/5252 , C04B2235/5264 , C04B2235/5268 , C04B2235/6028 , D03D15/0083 , D03D25/005 , D10B2101/08 , D10B2401/062 , D10B2401/063 , D10B2505/02 , F01D5/284 , F05D2300/2261 , F05D2300/2283 , F05D2300/614 , Y10T428/24058 , Y10T428/24107 , Y10T428/24132 , Y10T428/24149 , Y10T428/24157 , Y10T428/249929 , Y10T428/2973 , Y10T442/3195 , Y10T442/322
摘要： A preform architecture and process for producing composite materials, and particularly CMC components. The process entails producing a composite component having a matrix material reinforced with a three-dimensional preform. The process includes producing first and second sets of tows containing filaments. Each tow of the first set has a predetermined cross-sectional shape and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material. The preform is then fabricated from the first and second sets of tows, in which the second set of tows are transverse to the first set of tows, adjacent tows of the second set are spaced apart to define interstitial regions therebetween, and the cross-sectional shapes of the first set of tows are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.
摘要翻译：用于生产复合材料的预型体结构和工艺，特别是CMC组件。该方法需要生产具有用三维预成型体增强的基体材料的复合部件。该方法包括产生含有长丝的第一组和第二组丝束。第一组的每个丝束具有预定的横截面形状，并且嵌入由不是基质材料或基质材料的前体的材料形成的临时基质材料中。然后从第一组和第二组丝束制造预成型件，其中第二组丝束横向于第一组丝束，相邻的第二组丝束间隔开以限定它们之间的间隙区域，并且横截面第一组丝束的形状基本上与间隙区域的横截面形状一致，以便基本上填充间隙区域。

8. 发明申请

US20110229337A1 HYBRID CERAMIC MATRIX COMPOSITE TURBINE BLADES FOR IMPROVED PROCESSIBILITY AND PERFORMANCE AND PROCESS FOR PRODUCING HYBRID TURBINE BLADES 审中-公开
标题翻译：混合陶瓷基体复合涡轮叶片，用于改进混合涡轮叶片的可行性和性能及工艺
公开(公告)号：US20110229337A1
公开(公告)日：2011-09-22
申请号：US12828266
申请日：2010-06-30
申请人： Douglas Melton Carper , Suresh Subramanian , Richard William Jendrix , James Dale Steibel
发明人： Douglas Melton Carper , Suresh Subramanian , Richard William Jendrix , James Dale Steibel
IPC分类号： F01D5/14 , C03B29/00
CPC分类号： C04B35/565 , B32B18/00 , B32B2311/22 , B32B2315/02 , C04B35/62863 , C04B35/62868 , C04B35/62871 , C04B35/62873 , C04B2235/422 , C04B2235/428 , C04B2235/5244 , C04B2235/5248 , C04B2235/5256 , C04B2235/5268 , C04B2235/616 , C04B2235/80 , C04B2237/361 , C04B2237/363 , C04B2237/365 , C04B2237/368 , C04B2237/38 , C04B2237/61 , F01D5/282 , F01D5/284 , F05D2300/2261 , F05D2300/603 , Y02T50/67 , Y02T50/672
摘要： 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 a melt infiltration (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.
摘要翻译：本发明是一种混合陶瓷基复合涡轮发动机部件，其包括外壳部分和内芯部分，其中外壳部分和内芯部分使用熔融渗透（MI）工艺。外壳部分包括使用选自淤浆浇铸MI工艺和预浸料MI工艺的工艺制造的SiC / SiC材料。内芯部分包括选自Si / SiC复合材料和单块陶瓷材料的材料。 Si / SiC复合材料可以使用Silcomp工艺制造。本发明可以是高压涡轮叶片，高压涡轮叶片，低压涡轮叶片或低压涡轮叶片。本发明也是制造混合陶瓷基复合涡轮发动机部件的方法。

9. 发明授权

US07837914B2 Process of producing a composite component and intermediate product thereof 有权
标题翻译：复合成分及其中间体的制造方法
公开(公告)号：US07837914B2
公开(公告)日：2010-11-23
申请号：US11566370
申请日：2006-12-04
申请人： Timothy Daniel Kostar , Douglas Melton Carper , Suresh Subramanian , James Dale Steibel
发明人： Timothy Daniel Kostar , Douglas Melton Carper , Suresh Subramanian , James Dale Steibel
IPC分类号： C04B35/00 , B29C44/04
CPC分类号： D03D15/00 , C04B35/80 , C04B2235/5244 , C04B2235/5252 , C04B2235/5264 , C04B2235/5268 , C04B2235/6028 , D03D15/0083 , D03D25/005 , D10B2101/08 , D10B2401/062 , D10B2401/063 , D10B2505/02 , F01D5/284 , F05D2300/2261 , F05D2300/2283 , F05D2300/614 , Y10T428/24058 , Y10T428/24107 , Y10T428/24132 , Y10T428/24149 , Y10T428/24157 , Y10T428/249929 , Y10T428/2973 , Y10T442/3195 , Y10T442/322
摘要： A preform architecture and process for producing composite materials, and particularly CMC components. The process entails producing a composite component having a matrix material reinforced with a three-dimensional preform. The process includes producing first and second sets of tows containing filaments. Each tow of the first set has a predetermined cross-sectional shape and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material. The preform is then fabricated from the first and second sets of tows, in which the second set of tows are transverse to the first set of tows, adjacent tows of the second set are spaced apart to define interstitial regions therebetween, and the cross-sectional shapes of the first set of tows are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.
摘要翻译：用于生产复合材料的预型体结构和工艺，特别是CMC组件。该方法需要生产具有用三维预成型体增强的基体材料的复合部件。该方法包括产生含有长丝的第一组和第二组丝束。第一组的每个丝束具有预定的横截面形状，并且嵌入由不是基质材料或基质材料的前体的材料形成的临时基质材料中。然后从第一组和第二组丝束制造预成型件，其中第二组丝束横向于第一组丝束，相邻的第二组丝束间隔开以限定它们之间的间隙区域，并且横截面第一组丝束的形状基本上与间隙区域的横截面形状一致，以便基本上填充间隙区域。

10. 发明授权

US07754126B2 Interlaminar tensile reinforcement of SiC/SiC CMC's using fugitive fibers 有权
标题翻译： SiC / SiC CMC使用逃逸纤维的层间拉伸强化
公开(公告)号：US07754126B2
公开(公告)日：2010-07-13
申请号：US11155190
申请日：2005-06-17
申请人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper
发明人： Suresh Subramanian , James Dale Steibel , Douglas Melton Carper
IPC分类号： B29C70/40 , C04B35/64 , F01D5/14
CPC分类号： F01D5/28 , C04B35/573 , C04B35/806 , C04B38/065 , C04B2111/00982 , C04B2235/5212 , C04B2235/5244 , C04B2235/5252 , C04B2235/5256 , C04B2235/5268 , C04B2235/616 , F05D2300/222 , F05D2300/224 , F05D2300/601 , F05D2300/6012 , F05D2300/603 , Y02T50/67 , Y02T50/672 , Y10T29/49337 , C04B38/067 , C04B38/0675
摘要： A method of manufacturing a turbine engine component is disclosed. The method includes the steps of providing a plurality of ceramic cloth plies, each ply having woven ceramic fiber tows and at least one fugitive fiber tow, laying up the plurality of plies in a preselected arrangement to form a turbine engine component shape, oxidizing the fugitive fibers to produce fugitive fiber void regions in the ply, rigidizing the component shape to form a coated component preform using chemical vapor infiltration, partially densifying the coated component preform using carbon-containing slurry, and further densifying the coated component preform with at least silicon to form a ceramic matrix composite turbine engine component having matrix rich regions.
摘要翻译：公开了一种制造涡轮发动机部件的方法。该方法包括以下步骤：提供多个陶瓷布层，每个层具有编织的陶瓷纤维丝束和至少一个短纤维丝束，以预选布置布置多个层以形成涡轮发动机部件的形状，从而氧化该流体纤维以在帘布层中产生短纤维空隙区域，使组分形状硬化，以形成使用化学气相渗透的涂层组分预成型件，使用含碳浆料部分致密化涂覆的组件预成型体，并进一步使至少具有硅的致密化涂层组件预制件形成具有基质富集区域的陶瓷基复合涡轮发动机部件。

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