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Turbine Engine Component Comprising a Ceramic Matrix

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Turbine Engine Component Comprising a Ceramic Matrix (19) TZZ¥_¥ _T (11) EP 3 138 829 B1 (12) EUROPEAN PATENT SPECIFICATION (45) Date of publication and mention (51) Int Cl.: of the grant of the patent: C04B 35/56 (2006.01) C04B 35/565 (2006.01) 23.05.2018 Bulletin 2018/21 C04B 35/58 (2006.01) C04B 35/80 (2006.01) C04B 35/628 (2006.01) F01D 5/28 (2006.01) (2006.01) (2006.01) (21) Application number: 16185085.4 F23R 3/00 F23M 5/00 (22) Date of filing: 22.08.2016 (54) TURBINE ENGINE COMPONENT COMPRISING A CERAMIC MATRIX COMPOSITE INCLUDING SILICON CARBIDE FIBERS IN A CERAMIC MATRIX COMPRISING A MAX PHASE COMPOUND TURBINENMOTORKOMPONENT ENTHALTEND EINEN VERBUNDWERKSTOFF MIT KERAMISCHER MATRIX MIT SILICIUMCARBIDFASERN IN EINER KERAMISCHEN MATRIX MIT EINER MAX-PHASE-VERBINDUNG COMPOSANT DE MOTEUR DE TURBINE COMPRENANT UN COMPOSITE À MATRICE CÉRAMIQUE COMPRENANT DES FIBRES DE CARBURE DE SILICIUM DANS UNE MATRICE EN CÉRAMIQUE COMPRENANT UN COMPOSÉ DE PHASE MAX (84) Designated Contracting States: (72) Inventors: AL AT BE BG CH CY CZ DE DK EE ES FI FR GB • Harris, Stephen GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO Long Beach, CA 90803 (US) PL PT RO RS SE SI SK SM TR • Shinavski, Robert Mission Viejo, CA 92691 (US) (30) Priority: 28.08.2015 US 201562211326 P (74) Representative: Rolls-Royce plc (43) Date of publication of application: Intellectual Property Dept SinA-48 08.03.2017 Bulletin 2017/10 PO Box 31 Derby DE24 8BJ (GB) (73) Proprietor: Rolls-Royce High Temperature Composites Inc (56) References cited: Huntington Beach, CA 92648 (US) CN-A- 101 508 591 CN-A- 104 628 407 US-A1- 2010 009 143 US-A1- 2011 170 653 US-A1- 2015 008 613 Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). EP 3 138 829 B1 Printed by Jouve, 75001 PARIS (FR) 1 EP 3 138 829 B1 2 Description Ta2GaC, Hf2SnC, Hf2PbC, Hf2SnN, Hf2SC, Ti3AlC2, V3AlC2, Ti3SiC2, Ti3GeC2, Ti3SnC2, Ta3AlC2, TECHNICAL FIELD Ti4AlN3, V4AlC3, Ti4GaC3, Ti4SiC3, Ti4GeC3, Nb4AlC3, and Ta4AlC3. [0001] The present disclosure is directed generally to 5 [0008] The MAX phase compound may be selected ceramic matrix composites and more particularly to a tur- from the group consisting of: Ti2AlC, Ti2AlN, Ti3SiC2, bine engine component comprising a silicon carbide fib- Ti4AlN3 and Ti4SiC3. er-based composite that may have improved fracture [0009] The concentration of the silicon carbide in the toughness and other properties. ceramic matrix is from 1 wt.% to 40 wt.%. 10 [0010] The ceramic matrix may further comprise a sil- BACKGROUND icide. [0011] The silicide may be selected from the group [0002] Ceramic matrix composites, which include ce- consisting of titanium silicide, vanadium silicide, chromi- ramicfibers embedded ina ceramicmatrix, exhibit acom- um silicide, sc andium silicide, zirconium s ilicide, niobium bination of properties that make them promising candi- 15 silicide, molybdenum silicide, hafnium silicide and tanta- dates for industrial and aerospace applications that de- lum silicide. mand excellent thermal and mechanical properties along [0012] The ceramic matrix may comprise no more than with low weight. For example, SiC/SiC composites in- about 5 wt.% unreacted silicon. cluding SiC fibers in a SiC matrix are being developed [0013] According to various examples there is provid- for use in gas turbine engines and nuclear applications. 20 ed a ceramic matrix composite (CMC) part comprising [0003] MAX phase compounds are a family of layered at least one component comprising the ceramic matrix hexagonal carbides and nitrides having a chemical com- composite as described in the preceding paragraphs. position Mn+1AXn, where M is an early transition metal, [0014] The component may be selected from the group A is an A-group element usually selected from groups consisting of: blade seal segments, blades, vanes, and IIIA or IVA of the periodic table, X is either carbon or25 combustion liners. nitrogen, and n is an integer selected from 1, 2 or 3. US [0015] A method of making a ceramic matrix composite 2010/009143 A1 describes a CMC comprising coated is also disclosed, said method comprising: (a) infiltrating SiC fibers in a matrix comprising several phases among a porous fiber preform comprising coated silicon carbide which, i.e. a Mn+1AXn phase with M=Ti, A=Si, n=2, and fibers with a slurry comprising solid particulate matter, mentions a preform made from continuous fibers. This 30 where the solid particulate matter includes silicon carbide document contains an example where the matrix com- particles and at least one MAX phase precursor, thereby prises TiB2, TiC, Ti3SiC2, SiC, and TiSi2, but does not forming an impregnated fiber preform; (b) infiltrating the mention the proportion of MAX phase/SiC in the matrix, impregnated fiber preform with a melt comprising silicon; nor any turbine engine component. and (c) forming a ceramic matrix composite comprising [0004] A nuclear lining made of a CMC comprising SiC 35 silicon carbide fibers in a ceramic matrix, where the ce- fibers coated with an interphase, and a matrix comprising ramic matrix comprises silicon carbide and a MAX phase Ti3SiC2 and 5-15 vol% SiC is known from UScompound having a chemical composition n+1MAXn, 2011/170653 A1. A CMC article comprising coated SiC where M is a transition metal selected from the group fibers in a matrix of SiC, used for turbine parts, is known consisting of: Ti, V, Cr, Sc, Zr, Nb, Mo, Hf, and Ta; A is from US 2015/008613 A1. 40 a group-A element selected from the group consisting of: Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, TI and Pb, and X is BRIEF SUMMARY carbon or nitrogen, with n being an integer from 1 to 3. [0016] The melt may comprise a silicon alloy. [0005] According to various examples there is provid- [0017] The melt may further comprise the transition ed a turbine engine component comprising a ceramic 45 metal. matrix composite including continuous silicon carbide fib- [0018] The melt may further comprise the group-A el- ers in a ceramic matrix comprising silicon carbide and a ement. MAX phase compound as described in claim 1. [0019] The melt may comprise the silicon alloy at a [0006] The concentration of the MAX phase compound eutectic composition thereof. is from 60 wt.% to 99 wt.%. 50 [0020] The melt may be at a temperature less than a [0007] The MAX phase compound may be selected melting temperature of silicon. from the group consisting of: Ti2CdC, Sc2InC, Ti2AlC, [0021] The at least one MAX phase precursor may Ti2GaC, Ti2InC, Ti 2TlC, V2AlC, V2GaC, Cr 2GaC, Ti 2AlN, comprise a carbide, nitride or hydride comprising the Ti2GaN, Ti2InN, V2GaN, Cr2GaN, Ti2GeC, Ti2SnC, transition metal. 55 Ti2PbC, V2GeC, Cr2AlC, Cr2GeC, V2PC, V2AsC, Ti2SC, [0022] The at least one MAX phase precursor may Zr2InC, Zr2TlC, Nb2AlC, Nb2GaC, Nb2InC, Mo2GaC, comprise a carbide, nitride or hydride comprising the Zr2InN, Zr2TlN, Zr2SnC, Zr2PbC, Nb2SnC, Nb2PC, group-A element. Nb2AsC, Zr2SC, Nb2SC, Hf2InC, Hf2TlC, Ta2AlC, 2 3 EP 3 138 829 B1 4 BRIEF DESCRIPTION OF THE DRAWINGS [0034] In a ninth example, M is Ta and the MAX phase compound may be selected from among:2 AlC,Ta [0023] FIG. 1 is a flow chart showing exemplary steps Ta2GaC, Ta3AlC2, and Ta4AlC3. in fabricating a ceramic matrix composite. [0035] Due to the improved fracture toughness, ther- 5 mal shock resistance and machinability of MAX phase DETAILED DESCRIPTION compounds compared to silicon carbide, it is advanta- geous for the ceramic matrix to include a substantial frac- [0024] Described herein is a ceramic matrix composite tion of the MAX phase. For example, the concentration that may exhibit increased fracture toughness, improved of the MAX phase compound in the ceramic matrix may machinability, high thermal shock resistance, and/or10 be at least about 70 wt.%, at least about 80 wt.%, or at good thermal and electrical conductivity due to the pres- leastabout 90 wt.%. Typically, theMAX phasecompound ence of a MAX phase within the ceramic matrix. MAX is present at a concentration in the ceramic matrix of no phase compounds have been shown to exhibit benefits more than 99 wt.%, or no more than 95 wt.%. over typical carbides and nitrides, including improved [0036] The silicon carbide is present in the ceramic ma- ductility due to their layered structure. The ceramic matrix 15 trix at a concentration of from 1 wt.% to 40 wt.%. For composite comprises a framework of silicon carbide fib- example, the concentration of the silicon carbide may be ers in a ceramic matrix comprising silicon carbide and a at least about 5 wt.%, at least about 10 wt.%, at least MAX phase compound. about 20 wt.%, at least about 30 wt.%. [0025] The MAX phase compound has a chemical [0037] The ceramic matrix composite described herein 20 composition Mn+1AXn, where M is a transition metal se- may form all or part of a ceramic matrix composite part lected from among: Ti, V, Cr, Sc, Zr, Nb, Mo, Hf, and Ta, that may require, among other properties, high fracture A is a group-A element selected from among: Al, Si, P, toughness and good thermal shock resistance. The ce- S, Ga, Ge, As, Cd, In, Sn, TI and Pb, and X is carbon or ramic matrix composite is a turbine engine component, nitrogen, with n being an integer from 1 to 3.
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