FIELD

The present subject matter relates generally to processing composite components, such as ceramic matrix composite (CMC) components. More particularly, the present subject matter relates to systems and methods for thermally processing composite components.

BACKGROUND

A gas turbine engine generally includes a fan and a core arranged in flow communication with one another. Additionally, the core of the gas turbine engine general includes, in serial flow order, a compressor section, a combustion section, a turbine section, and an exhaust section. In operation, air is provided from the fan to an inlet of the compressor section where one or more axial compressors progressively compress the air until it reaches the combustion section. Fuel is mixed with the compressed air and burned within the combustion section to provide combustion gases. The combustion gases are routed from the combustion section to the turbine section. The flow of combustion gases through the turbine section drives the turbine section and is then routed through the exhaust section, e.g., to atmosphere.

Typically, components inside the combustion and turbine sections are complex to manufacture due to their geometries. Moreover, the working environment for such components is extremely severe due to the high temperature and pressures. Accordingly, components within the flow path of the combustion gases have strict requirements for their geometrical profiles and temperature tolerance to maintain desired efficiency of the engine. As ceramic matrix composite (CMC) materials can better withstand such severe environments than traditional materials, there is particular interest in replacing components formed of traditional materials inside gas turbine engine with CMC materials.

Composite components typically undergo thermal processing during manufacture. For instance, composite components may undergo a compaction or debulking process, a burnout process, and a densification process, such as e.g., a melt-infiltration process, a polymer impregnation and pyrolysis process, or a chemical vapor infiltration process. Thermally processing composite components has presented certain challenges. For instance, typically each thermal process is performed by a separate thermal system, e.g., an autoclave or furnace. For example, the components may be processed in an autoclave during compaction, moved to a furnace for the burnout process, and then moved to another thermal system for melt-infiltration. Moving the components from thermal system to thermal system prevents contamination between the processes, but requires significant floor space and requires extensive cost and upkeep to maintain the thermal system. Moreover, transporting the components from system to system is time consuming and provides opportunities for the parts to become damaged. Moreover, the chambers or interior volumes within the thermal systems are typically large and can require time and significant energy to heat, pressurize, or create a vacuum within; thus, operating such thermal systems is expensive, and in many instances, inefficient.

Accordingly, improved systems and methods that address one or more of the challenges noted above would be useful.

BRIEF DESCRIPTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one exemplary aspect, the present disclosure is directed to a method for manufacturing a composite component. The method includes placing a first vessel having a preform disposed therein into a chamber defined by a thermal system. The method also includes compacting, by the thermal system, the preform within the first vessel at an elevated temperature and an elevated pressure to transition the preform to a green-state part. Further, the method includes removing the green-state part from the first vessel. The method also includes placing a second vessel having the green-state part disposed therein into the chamber of the thermal system. In addition, the method includes burning out, by the thermal system, the green-state part within the second vessel at an elevated temperature and under vacuum to transition the green-state part to a burnt-out part. Moreover, the method includes removing the burnt-out part from the second vessel. The method also includes placing a third vessel having the burnt-out part disposed therein into the chamber of the thermal system. The method further includes densifying, by the thermal system, the burnt-out part within the third vessel at an elevated temperature and under vacuum to transition the burnt-out part to the composite component.

In another exemplary aspect, the present disclosure is directed to a system for manufacturing a composite component. The system includes a thermal system defining a chamber. The system also includes a plurality of vessels each removably mountable within the chamber, wherein the composite component is removably insertable into a volume of any one of the plurality of vessels. The system also includes a mover device for inserting and removing the composite component into and from any one of the plurality of vessels and mounting and removing any one of the plurality of vessels to and from the chamber of the thermal system. The system also includes a control system comprising a controller communicatively coupled with the thermal system and the mover device. The controller is configured to control the mover device to mount a first vessel of the plurality of vessels having the composite component in a first state into the chamber of the thermal system; activate the thermal system to perform a first thermal process to transition the composite component from the first state to a second state; control the mover device to remove the first vessel having the composite component in the second state from the chamber of the thermal system; control the mover device to insert the composite component in the second state into a second vessel of the plurality of vessels; control the mover device to mount the second vessel having the composite component in the second state into the chamber of the thermal system; and activate the thermal system to perform a second thermal process to transition the composite component from the second state to a third state.

In another exemplary aspect, the present disclosure is directed to a method for manufacturing a component. The method includes placing a first vessel having the component disposed therein into a chamber defined by a thermal system, wherein during placing the first vessel, the component is in a first state. Further, the method includes performing, by the thermal system, a first thermal process to transition the component from the first state to a second state. Moreover, the method includes placing a second vessel having the component disposed therein into the chamber of the thermal system, wherein during placing the second vessel, the component is in the second state. In addition, the method includes performing, by the thermal system, a second thermal process to transition the component from the second state to a third state.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

