Ceramic matrix composite component with modified thermal expansion and method for producing the same

Abstract

A ceramic matrix composite (CMC) material component is provided that includes a CMC material and an environmental barrier coating (EBC). The CMC material includes first fibers, a matrix, and at least one coefficient of thermal expansion (CTE) increasing additive. The first fibers include a first material having a first CTE value. The matrix includes a second material having a second CTE value. The at least one CTE increasing additive has a third CTE value. The EBC is disposed on at least one exposed surface of the CMC material and has a fourth CTE value. The third CTE value is greater than the first CTE value and the second CTE value, and the at least one CTE increasing additive is present within the CMC material in an amount that elevates a CTE value of the CMC material above the first CTE value or the second CTE value.

What is claimed is: 
     
         1 . A method of producing a ceramic matrix material (CMC) component, comprising:
 producing a CMC material, including:
 providing a plurality of first fibers comprising a first material, the first material having a first coefficient of thermal expansion (CTE) value; 
 incorporating a matrix with the plurality of first fibers, the matrix comprising a second material having a second CTE value; 
 incorporating at least one CTE increasing additive having a third CTE value; and 
   disposing an environmental barrier coating (EBC) on at least one exposed surface of the CMC material, the EBC having a fourth CTE value;   wherein the third CTE value is greater than the first CTE value and the second CTE value, and the CTE increasing additive is present within the CMC in an amount that elevates a CTE value of the CMC above the first CTE value or the second CTE value.   
     
     
         2 . The method of  claim 1 , wherein the at least one CTE increasing additive is incorporated into the plurality of first fibers. 
     
     
         3 . The method of  claim 1 , wherein the at least one CTE increasing additive is provided as fibers, and the CTE increasing additive fibers are incorporated with the plurality of first fibers to produce a plurality of fiber tows and are incorporated into the CMC. 
     
     
         4 . The method of  claim 3 , wherein the at least one CTE increasing additive fibers are a first CTE increasing additive, and the at least one CTE increasing additive includes a second CTE increasing additive that is incorporated into the matrix. 
     
     
         5 . The method of  claim 4 , wherein the second CTE increasing additive is incorporated into the matrix in particulate form. 
     
     
         6 . The method of  claim 1 , wherein the at least one CTE increasing additive is incorporated into the matrix. 
     
     
         7 . The method of  claim 6 , wherein the first CTE increasing additive is incorporated into the matrix in particulate form. 
     
     
         8 . The method of  claim 1 , wherein the fourth CTE value and the CTE value of the CMC material are sufficiently close to one another such that the EBC is thermo-mechanically stable on the at least one exposed surface of the CMC material. 
     
     
         9 . The method of  claim 1 , wherein the fourth CTE value is equal to or greater than the CTE value of the CMC material. 
     
     
         10 . The method of  claim 1 , wherein the first material is SiC, the at least one CTE increasing additive includes at least one of Al 2 O 3 , ZrO 2 —Y 2 O 3 , or MoSi 2 , and the EBC is a rare-earth monosilicate. 
     
     
         11 . The method of  claim 1 , wherein the at least one CTE increasing additive comprises Al 2 O 3 . 
     
     
         12 . The method of  claim 1 , wherein the at least one CTE increasing additive comprises ZrO 2 —Y 2 O 3 . 
     
     
         13 . The method of  claim 1 , wherein the at least one CTE increasing additive comprises MoSi 2 . 
     
     
         14 . A ceramic matrix composite (CMC) material component, comprising:
 a CMC material comprising:
 a plurality of first fibers comprising a first material, the first material having a first coefficient of thermal expansion (CTE) value; 
 a matrix incorporated with the plurality of fibers, the matrix comprising a second material having a second CTE value; 
 at least one CTE increasing additive having a third CTE value; and 
   an environmental barrier coating (EBC) disposed on at least one exposed surface of the CMC material, the EBC having a fourth CTE value;   wherein the third CTE value is greater than the first CTE value and the second CTE value, and the at least one CTE increasing additive is present within the CMC material in an amount that elevates a CTE value of the CMC material above the first CTE value or the second CTE value.   
     
     
         15 . The CMC material component of  claim 14 , wherein the at least one CTE increasing additive comprises Al 2 O 3 . 
     
     
         16 . The CMC material component of  claim 14 , wherein the at least one CTE increasing additive comprises MoSi 2 . 
     
     
         17 . The CMC material component of  claim 14 , wherein the first material comprises carbon fibers and the matrix is a carbon matrix. 
     
     
         18 . The CMC material component of  claim 14 , wherein the first material comprises carbon fibers and the matrix is a SiC matrix. 
     
     
         19 . The CMC material component of  claim 14 , wherein the first material comprises SiC fibers and the matrix is a carbon matrix. 
     
     
         20 . The CMC material component of  claim 14 , wherein the first material comprises Al 2 O 3  and the matrix is an Al 2 O 3  matrix.