Ceramic matrix composite turbine nozzle shell and method of assembly

1. A method of manufacturing a ceramic matrix composite (CMC) turbine nozzle shell, the method comprising:

stacking and de-bulking a first plurality of platform plies to assemble a primary outer nozzle platform;

stacking and de-bulking a second plurality of platform plies to assemble a primary inner nozzle platform;

stacking a plurality of trailing edge plies in a V-shape;

assembling a core and trailing edge preform by wrapping a plurality of core plies around a tool having a wider end and a narrower end to define a hollow airfoil shape and by arranging the stacked trailing edge plies adjacent the narrower end of the plurality of core plies;

assembling an airfoil-shaped body by:

circumferentially wrapping a set of composite wrap plies around the core and trailing edge preform, each composite wrap ply of the set of composite wrap plies having a first layer with first unidirectional fibers oriented in parallel to a longitudinal axis of the CMC turbine nozzle shell and a second layer having unidirectional fibers oriented in a transverse direction relative to the first unidirectional fibers, wherein each composite wrap ply has a first longitudinal edge and a second longitudinal edge;

cutting the first longitudinal edge and the second longitudinal edge into fingers; and

folding the fingers in a transverse direction away from the core plies and interleaving the fingers of each composite wrap ply between secondary platform plies to define a secondary inner nozzle platform and a secondary outer nozzle platform;

joining the primary outer nozzle platform to the secondary outer nozzle platform; and

joining the primary inner nozzle platform to the secondary inner nozzle platform,

wherein:

the primary outer nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially outward from the composite wrap plies defining the airfoil shape;

the primary inner nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially inward from the composite wrap plies defining the airfoil shape; or

the primary outer nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially outward from the composite wrap plies defining the airfoil shape and the primary inner nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially inward from the composite wrap plies defining the airfoil shape.

2. The method of claim 1 , wherein the steps of forming the primary outer nozzle platform and forming the primary inner nozzle platform are performed simultaneously.

3. The method of claim 1 , wherein the platform plies in the first plurality of platform plies comprise first platform plies with unidirectional fibers oriented in a first fiber direction and second platform plies with unidirectional fibers oriented in a second fiber direction transverse to the first fiber direction; and wherein the stacking and de-bulking of the first plurality of platform plies in the assembling of the primary outer nozzle platform comprises alternating the first platform plies with the second platform plies.

4. The method of claim 3 , wherein the assembling of the primary outer nozzle platform further comprises green-machining of the stacked and de-bulked first plurality of platform plies.

5. The method of claim 1 , wherein the platform plies in the second plurality of platform plies comprise third platform plies with unidirectional fibers oriented in a third fiber direction and fourth platform plies with unidirectional fibers oriented in a fourth fiber direction transverse to the third fiber direction; and wherein the stacking and de-bulking of the second plurality of platform plies in the assembling of the primary inner nozzle platform comprises alternating the third platform plies with the fourth platform plies.

6. The method of claim 5 , wherein the assembling of the primary inner nozzle platform further comprises green-machining of the stacked and de-bulked second plurality of platform plies.

7. The method of claim 1 , wherein the step of assembling the airfoil-shaped body further comprises circumferentially wrapping each composite wrap ply of the set of composite wrap plies around the core and trailing edge preform, such that each first layer and each second layer are wrapped in alternating arrangement around the core plies.

8. The method of claim 1 , wherein the assembling of the airfoil-shaped body further comprises disposing a plurality of filler panels radially outward of the folded fingers of each composite wrap ply, such that a substantially uniform ply layer is interleaved between the secondary platform plies.

9. The method of claim 1 , further comprising rolling up one or more plies to produce a first concave fillet and circumscribing the airfoil-shaped body at a joint between the airfoil-shaped body and the secondary outer nozzle platform with the first concave fillet.

10. The method of claim 1 , further comprising rolling up one or more plies to produce a second concave fillet and circumscribing the airfoil-shaped body at a joint between the airfoil-shaped body and the secondary inner nozzle platform with the second concave fillet.

11. The method of claim 1 , further comprising the step of rigidizing the airfoil-shaped body, the outer nozzle platform, and the inner nozzle platform, after the steps of joining the primary outer nozzle platform to the secondary outer nozzle platform of the airfoil-shaped body and joining the primary inner nozzle platform to the secondary inner nozzle platform of the airfoil-shaped body; and wherein the step of rigidizing produces a rigidized CMC turbine nozzle.

12. The method of claim 11 , further comprising densifying the rigidized CMC turbine nozzle using a melt-infiltration process.

13. The method of claim 1 , wherein the primary outer nozzle platform includes the plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially outward from the composite wrap plies defining the airfoil shape.

14. The method of claim 1 , wherein the primary inner nozzle platform includes the plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially inward from the composite wrap plies defining the airfoil shape.

15. The method of claim 1 , wherein the primary outer nozzle platform and the primary inner nozzle platform each extends radially outward from the core plies in the transverse direction away from the longitudinal axis.

16. The method of claim 1 , wherein the primary outer nozzle platform includes the plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially outward from the composite wrap plies defining the airfoil shape and the primary inner nozzle platform includes the plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially inward from the composite wrap plies defining the airfoil shape.