Systems for forming a ceramic matrix composite structure, and related advanced fiber placement apparatuses

Abstract

A method of forming a ceramic matrix composite structure. The method comprises forming at least one prepregged composite material comprising a ceramic fiber preform and a pre-ceramic matrix slurry. The at least one prepregged composite material is placed over at least one surface of a tool using an advanced fiber placement apparatus to form an at least partially uncured composite material structure. The at least partially uncured composite material structure is exposed at least to elevated temperatures to convert the at least partially uncured composite material structure into a ceramic matrix composite structure. A system for forming a ceramic matrix composite structure, an advanced fiber placement apparatus, and a ceramic matrix composite structure are also described.

1 . A system for forming a ceramic matrix composite structure, comprising:
 an advanced fiber placement apparatus comprising:
 a placement head configured to place at least one prepregged composite material over at least one surface of a tool, the at least one prepregged composite material comprising a ceramic fiber preform infiltrated with a pre-ceramic matrix slurry; and 
 at least one reel of the at least one prepregged composite material; 
   a curing apparatus configured to cure the at least partially uncured composite material structure to form a substantially cured composite material structure; and   a densification apparatus configured to densify the substantially cured composite material structure to form a ceramic matrix composite structure.   
     
     
         2 . The system of  claim 1 , wherein the advanced fiber placement apparatus is configured to draw, align, place, cut, and rethread the at least one prepregged composite material. 
     
     
         3 . The system of  claim 1 , wherein the advanced fiber placement apparatus is configured to place the at least one prepregged composite material over a contoured surface of a three-dimensional tool exhibiting a complex shape. 
     
     
         4 . The system of  claim 1 , wherein the advanced fiber placement apparatus is configured to manipulate at least one of the tackiness and rigidity of the at least one prepregged composite material before and during placement of the at least one prepregged composite material over the at least one surface of the tool. 
     
     
         5 . The system of  claim 1 , wherein the advanced fiber placement apparatus is configured to place multiple prepregged composite materials over the at least one surface of the tool simultaneously, sequentially, or a combination thereof. 
     
     
         6 . An advanced fiber placement apparatus comprising:
 at least one placement head configured to draw, align, place, cut, and rethread at least one prepregged composite material comprising a ceramic fiber preform infiltrated with a pre-ceramic matrix slurry; and   at least one reel of the at least one prepregged composite material.   
     
     
         7 . The advanced fiber placement apparatus of  claim 6 , wherein the at least one prepregged composite material comprises:
 a ceramic fiber preform comprising a single tow of ceramic fibers, a tape of multiple tows of ceramic fibers, or a woven fabric of multiple tows of ceramic fibers; and   pre-ceramic matrix slurry over and around the ceramic fiber preform.   
     
     
         8 . The advanced fiber placement apparatus of  claim 6 , wherein the at least one placement head is configured to cool the at least one prepregged composite material prior to placement over at least one surface of a tool and to heat the at least one prepregged composite material during placement over the at least one surface of the tool. 
     
     
         9 . (canceled) 
     
     
         10 . The advanced fiber placement apparatus of  claim 6 , wherein the at least one placement head is configured to increase one or more of the tackiness and the rigidity of the prepregged composite material prior to and during placement of the prepregged composite materials over the surface of the tool. 
     
     
         11 . The advanced fiber placement apparatus of  claim 6 , wherein the at least one prepregged composite material comprises an oxide-based ceramic fiber preform and an oxide-based pre-ceramic matrix slurry. 
     
     
         12 . The advanced fiber placement apparatus of  claim 11 , wherein the oxide-based ceramic fiber preform comprises one or more of alumina fibers, alumina-silica fibers, and alumina-boria-silica fibers. 
     
     
         13 . The advanced fiber placement apparatus of  claim 12 , wherein the oxide-based pre-ceramic matrix slurry comprises an oxide ceramic sol and an oxide ceramic filler. 
     
     
         14 . The advanced fiber placement apparatus of  claim 13 , wherein the oxide ceramic sol comprises one or more of alumina sol, a silica sol, and an alumina-silica sol, and wherein the oxide ceramic filler comprises particles of one or more of alumina, silica, and zirconia. 
     
     
         15 . The advanced fiber placement apparatus of  claim 6 , wherein the at least one prepregged composite material comprises a non-oxide-based ceramic fiber preform and a non-oxide-based pre-ceramic matrix slurry. 
     
     
         16 . The advanced fiber placement apparatus of  claim 15 , wherein the non-oxide-based ceramic fiber preform comprises one or more of silicon carbide fibers, silicon nitride fibers, fibers including silicon carbide on a carbon core, silicon carbide fibers containing titanium, silicon oxycarbide fibers, silicon oxycarbonitride fibers, and carbon fibers. 
     
     
         17 . The advanced fiber placement apparatus of  claim 15 , wherein the non-oxide-based pre-ceramic matrix slurry comprises a non-oxide pre-ceramic polymer and a non-oxide ceramic filler. 
     
     
         18 . The advanced fiber placement apparatus of  claim 17 , wherein the non-oxide pre-ceramic polymer is an organosilicon polymer formulated to form a non-oxide ceramic matrix through cure and pyrolysis, and wherein the non-oxide ceramic filler comprises particles of one or more of silicon carbide, silicon nitride, silicon hexaboride, aluminum nitride, boron nitride, boron carbide, titanium boride, titanium carbide, and hafnium carbide. 
     
     
         19 . The advanced fiber placement apparatus of  claim 6 , wherein the advanced fiber placement apparatus comprises multiple reels of the at least one prepregged composite material. 
     
     
         20 . An advanced fiber placement apparatus, comprising:
 reels of at least one prepregged composite material, each of the reels of prepregged composite material independently comprising at least one ceramic fiber preform infiltrated with at least one pre-ceramic matrix slurry; and   a placement head configured and positioned to draw and align the at least one prepregged composite material from the reels of prepregged composite material, to place a portion of the at least one prepregged composite material over a surface of a tool, and to cut the prepregged composite material after placement of the portion of the at least one prepregged composite material over the surface of the tool.   
     
     
         21 . The advanced fiber placement apparatus of  claim 20 , wherein the placement head is further configured to heat the portion of the at least one prepregged composite material prior to placement over the surface of the tool, and to cool another portion of the at least one prepregged composite material following placement of the portion of the at least one prepregged composite material over the surface of the tool.