Pre-form ceramic matrix composite cavity and method of forming and method of forming a ceramic matrix composite component

1. A method of forming pre-form ceramic matrix composite (CMC) cavity for a ceramic matrix component comprising steps of:

providing a mandrel;

applying a base ply to the mandrel;

laying-up at least one CMC ply on the base ply;

removing the mandrel;

densifying the base ply and the at least one CMC ply; and

wherein the densified base ply and at least one CMC ply form the pre form ceramic matrix component cavity having a desired geometry and a cavity formed therein, the cavity extending along an interior space in the component and wherein the cavity remains when the pre-form CMC cavity is subjected to subsequent laying up of additional CMC plies, autoclaving and densification.

2. The method of claim 1 , including an additional step prior to the step of applying the base ply to the mandrel of aligning a tip member adjacent to the mandrel.

3. The method of claim 2 , including an additional step after removing the mandrel of machining the tip member to remove additional material.

4. The method of claim 1 , including an additional step after removing the mandrel of laying-up a first set of CMC plies in a lay-up tool and applying the pre-form ceramic matrix composite cavity to the first set of CMC plies in the lay-up tool.

5. The method of claim 4 , including an additional step after the step of applying the pre-form ceramic matrix composite cavity of laying-up a second set of CMC plies to the pre-form ceramic matrix composite cavity.

6. The method of claim 5 , including an additional step after laying-up the second set of CMC plies of processing the first set of CMC plies, the pre-form ceramic matrix composite cavity, and the second set of CMC plies in the lay-up tool to form the ceramic matrix composite component.

7. The method of claim 1 , wherein the step of densifying includes melt infiltration or chemical vapor deposition.

8. The method of claim 1 , wherein the step of removing the mandrel includes heat or chemical removal methods.

9. A method of forming a ceramic matrix composite (CMC) component comprising steps of:

providing a lay-up tool having a first surface and a second surface;

applying a first base ply to the first surface of the lay-up tool;

laying-up a first set of CMC plies adjacent to the first base ply;

providing a pre-form ceramic matrix composite cavity comprising:

a cavity conforming to a mandrel geometry;

a densified base ply defining the cavity; and

at least one densified lay-up ply applied to the densified base ply, the pre-form ceramic matrix composite cavity having a desired geometry and the cavity formed therein, the cavity forming an interior space in the component;

placing the pre-form ceramic matrix composite cavity adjacent to the first set of CMC plies in the lay-up tool;

laying-up a second set of CMC plies adjacent to the pre-form ceramic matrix composite cavity;

applying a second base ply to the second set of CMC plies, the second base ply adjacent to the second surface of the lay-up tool;

after the step of applying the second base ply, autoclaving the first base ply, the first set of CMC plies, the pre-form ceramic matrix composite cavity, the second set of CMC plies, and the second base ply; and

densifying the first base ply, the first set of CMC plies, the pre-form ceramic matrix composite cavity, the second set of CMC plies, and the second base ply;

wherein the ceramic matrix composite is formed having a desired geometry and the cavity formed therein.

10. The method of claim 9 , wherein the ceramic matrix composite cavity includes a tip member.

11. The method of claim 9 , including an additional step of after the step of densifying of inserting a tip member into the pre-from ceramic matrix composite cavity.

12. The method of claim 9 , including an additional step after the step of densifying of machining the ceramic matrix composite to a desired geometry.

13. The method of claim 9 , wherein the step of densifying includes melt infiltration or chemical vapor deposition.

14. The method of claim 9 , including an additional step of after the step of autoclaving of removing the tool.

15. The method of claim 14 , including an additional step after the step of removing the tool of burn-out of the first base ply, the first set of CMC plies, the pre-form ceramic matrix composite cavity, the second set of CMC plies, and the second base ply.