CMC component with integral cooling channels and method of manufacture
A fiber-reinforced component for use in a gas turbine engine includes a fiber sleeve forming a cooling channel and a plurality of fiber plies enclosing the fiber sleeve, with the plurality of fiber plies forming first and second walls separated by the fiber sleeve. The fiber-reinforced component further includes a matrix material between fibers of the fiber sleeve and the plurality of fiber plies.
1. A fiber-reinforced component for use in a gas turbine engine, the fiber-reinforced component comprising:
a fiber sleeve forming a cooling channel, wherein the fiber sleeve comprises:
a first fiber sleeve layer forming an inner wall of the fiber sleeve and molded to form protrusions that extend into the cooling channel; and
a fiber fill material disposed on an outer surface of the first fiber sleeve layer in locations of the protrusions to fill regions defined by the protrusions;
a plurality of fiber plies enclosing the fiber sleeve, the plurality of fiber plies forming first and second walls separated by the fiber sleeve; and
a matrix material between fibers of the fiber sleeve and the plurality of fiber plies.
2. The fiber-reinforced component of claim 1 , wherein the fiber sleeve changes in cross-sectional shape along an axial length of the fiber sleeve.
3. The fiber-reinforced component of claim 1 , wherein the fiber sleeve changes in cross-sectional area along an axial length of the fiber sleeve.
4. The fiber-reinforced component of claim 1 , wherein the inner wall of the fiber sleeve is pressed together along at least a first portion of an axial length of the fiber sleeve to divide the fiber sleeve into a plurality of cooling channels along the first portion of axial length.
5. The fiber-reinforced component of claim 4 , wherein a second portion of the axial length of the fiber sleeve has a single cooling channel.
6. The fiber-reinforced component of claim 1 , wherein the protrusions comprise a plurality of rings formed around the fiber sleeve and spaced along an axial length of the fiber sleeve.
7. The fiber-reinforced component of claim 1 , wherein the protrusions form a helix around the fiber sleeve.
8. The fiber-reinforced component of claim 1 , wherein the fiber sleeve further comprises:
a second fiber sleeve layer forming an outer wall of the fiber sleeve, the outer wall disposed around the fiber fill material and first fiber sleeve layer.
9. The fiber-reinforced component of claim 1 , wherein the fiber fill material comprises a structure selected from the group consisting of a plurality of fiber rings and a fiber tow wrapped around the first fiber sleeve layer.
10. The fiber-reinforced component of claim 1 , wherein the fiber sleeve comprises a triaxial braid.
11. The fiber-reinforced component of claim 1 , wherein the matrix material comprises a ceramic.
12. A method for manufacturing a fiber-reinforced component with integral fiber-formed cooling channels for use in a gas turbine engine, the method comprising:
forming a fiber sleeve, wherein the fiber sleeve forms a cooling channel; wherein forming the fiber sleeve comprises:
molding a first fiber sleeve layer to form protrusions that extend into the cooling channel; and
disposing a fiber fill material on an outer surface of the first fiber sleeve layer in locations of the protrusions to fill regions defined by the protrusions;
enclosing the fiber sleeve and the fiber fill material with a plurality of fiber plies to form a fiber preform of a component with internal cooling provided by the cooling channel; and
densifying the fiber preform with a matrix material disposed between fibers of the fiber sleeve and the plurality of fiber plies.
13. The method of claim 12 , and further comprising densifying the fiber sleeve prior to enclosing the fiber sleeve with the plurality of fiber plies.
14. The method of claim 12 , wherein the fiber sleeve is formed with a reduced cross-sectional area along an axial length of the fiber sleeve.
15. The method of claim 12 , and further comprising consolidating the fiber sleeve by flattening the fiber along at least a portion of an axial length of the fiber sleeve to change a cross-sectional shape of the cooling channel.
16. The method of claim 12 , and further comprising consolidating the fiber sleeve by pressing the first fiber sleeve layer together along at least a portion of an axial length of the fiber sleeve to divide the fiber sleeve into a plurality of cooling channels along the portion of axial length.
17. The method of claim 12 , wherein forming the fiber sleeve comprises:
applying molding structures to a mandrel;
forming the first fiber sleeve layer over the mandrel and molding structures to form an inner wall;
applying the fiber fill material to the outer surface of the first fiber sleeve layer in locations between molding structures to conform the inner wall to the molding structures;
forming a second fiber sleeve layer over the fiber fill material and first fiber sleeve layer to form an outer wall; and
removing the mandrel and molding structures from the fiber sleeve.
18. The method of claim 17 , wherein the fiber fill material comprises a structure selected from the group consisting of a plurality of fiber rings and a fiber tow wrapped around the outer surface of the first fiber sleeve.
19. The method of claim 18 , wherein the molding structures comprise a plurality of fiber rings or a fiber tow wrapped around the outer surface of the mandrel.