Granted Patent B2

US 12,649,697 · App. 17/832,459 · Granted Jun 9, 2026

Inventors: John S. Linck (Pueblo, CO); Christopher C. Koroly (Spring Valley, CA); Kirk Christopher Newton (Vail, AZ); Vijay V. Pujar (San Diego, CA); Paul T. Perea (Pueblo West, CO); James W. Rudolph (Colorado Springs, CO); Christopher T. Kirkpatrick (Pueblo West, CO); Katherine E. Waugh (Easton, CT)

Assignee: GOODRICH CORPORATION

C04B35/83C04B35/62873C04B35/62884C04B35/62894C04B2235/422C04B2235/5212C04B2235/5248C04B2235/5252C04B2235/5256C04B2235/602C04B2235/612C04B2235/614

Abstract

Claims (60)

1 . A method for manufacturing a C/C part, the method comprising:

heating a female forming tool and a first member to a shape forming temperature of between 65° C. and 205° C., the female forming tool comprising a metal material, the female forming tool comprising a die recess, the female forming tool extends longitudinally along a longitudinal centerline of the female forming tool between and to a first end of the female forming tool and a second end of the female forming tool, the female forming tool extends laterally between and to a first side of the female forming tool and a second side of the female forming tool, the die recess extends vertically into the female forming tool from a first top surface and a second top surface of the female forming tool to a recess surface of the female forming tool, and the first top surface and the second top surface are arranged on opposing sides of the recess surface at a top side of the female forming tool;

positioning an oxidized PAN fiber preform with the female forming tool;

forming the oxidized PAN fiber preform into a shaped body, the forming comprising:

moving the first member at least partially into the die recess, the first member shaped to be complementary to the die recess and comprising a metal material, the oxidized PAN fiber preform disposed between the first member and the female forming tool;

compressing the oxidized PAN fiber preform between the first member and the female forming tool, thereby increasing a fiber volume ratio of the oxidized PAN fiber preform;

bending the oxidized PAN fiber preform over a radii surface of the female forming tool, the radii surface forms a rounded, convex surface transition disposed between a sidewall portion of the recess surface at least partially defining the die recess and the first top surface of the female forming tool; and

clamping the oxidized PAN fiber preform directly between a first grip strip and the female forming tool while the oxidized PAN fiber preform is being compressed between the first member and the female forming tool, the first grip strip is located at the first top surface of the female forming tool and disposed along a periphery of the oxidized PAN fiber preform;

removing the shaped body from the female forming tool;

moving the shaped body into a graphite fixture having a contoured shape corresponding to a shape of the die recess of the female forming tool;

performing a carbonization process on the shaped body at a temperature of greater than about 1600° C. while the shaped body is in the graphite fixture;

moving the shaped body into a perforated graphite fixture, the perforated graphite fixture having a contoured shape corresponding to a shape of the die recess of the female forming tool and having a graphite paint disposed on contact surfaces;

depositing carbon on and within the shaped body via a first chemical vapor infiltration process performed at a temperature of between 900° C. to 1100° C. for between about 150 hours and about 650 hours while the shaped body is in the perforated graphite fixture, wherein the contact surfaces are configured to contact the shaped body during the first chemical vapor infiltration process;

performing a heat treat at a temperature of greater than 1600° C.;

performing a second chemical vapor infiltration process on the shaped body; and

performing a second heat treat at a temperature of about 1200° C. to about 2600° C.

2 . The method of claim 1 , further comprising applying at least one of:

a sizing agent to the oxidized PAN fiber preform prior to the oxidized PAN fiber preform being formed into the shaped body;

heat to the oxidized PAN fiber preform for a predetermined duration while the oxidized PAN fiber preform is held in compression in the die recess; or

steam to the oxidized PAN fiber preform for a predetermined duration while the oxidized PAN fiber preform is being formed into the shaped body or held in compression in the die recess.

3 . The method of claim 1 , further comprising:

clamping the oxidized PAN fiber preform directly between a second grip strip and the female forming tool along the periphery of the oxidized PAN fiber preform while the oxidized PAN fiber preform is being compressed between the first member and the female forming tool; and

the second grip strip is located at the second top surface of the female forming tool.

4 . The method of claim 1 , wherein the first member and the female forming tool are in direct contact with the oxidized PAN fiber preform.

5 . The method of claim 1 , wherein, in response to the forming the oxidized PAN fiber preform into the shaped body, a first portion of the oxidized PAN fiber preform is bent at an angle with respect to a second portion of the oxidized PAN fiber preform.

6 . The method of claim 5 , wherein the angle is between at least one of:

five degrees and one hundred and seventy-nine degrees; or

forty-five and one hundred and thirty-five degrees.

7 . The method of claim 1 , wherein the oxidized PAN fiber preform comprises a stack of sheets of non-crimp OPF fabric.

8 . The method of claim 1 , further comprising placing a dead weight onto the graphite fixture so as to hold the shaped body in compression with the graphite fixture during the carbonization process.

9 . The method of claim 1 , further comprising:

removing the shaped body from the perforated graphite fixture; and

machining the shaped body prior to the second chemical vapor infiltration process.

10 . The method of claim 9 , further comprising machining a surface of the shaped body between the first chemical vapor infiltration process and the second chemical vapor infiltration process.

11 . The method of claim 1 , further comprising fabricating the oxidized PAN fiber preform from a first sheet of a multi-axial, non-crimp, OPF fabric and a second sheet of the multi-axial, non-crimp, OPF fabric, wherein the first sheet is stacked and needled together with the second sheet to form the oxidized PAN fiber preform.

12 . The method of claim 11 , wherein the first sheet comprises at least one of a triaxial-tow or a quad-tow, the first sheet comprises a first plurality of fibers extending along a longitudinal direction, a second plurality of fibers oriented at a first angle with respect to the longitudinal direction, and a third plurality of fibers oriented at a second angle with respect to the longitudinal direction, wherein the first angle and the second angle are between twenty degrees and seventy degrees.

13 . The method of claim 12 , wherein the first angle is equal to the second angle, and the second plurality of fibers intersect the third plurality of fibers in a crisscross pattern.

14 . A method for manufacturing a C/C part, the method comprising:

fabricating an oxidized PAN fiber preform comprising a planar stack of sheets of OPF fabric;

heating a female forming tool and a first member to a shape forming temperature of between 65° C. and 205° C., the female forming tool comprising a die recess;

positioning the oxidized PAN fiber preform with the female forming tool;

forming the oxidized PAN fiber preform into a shaped body while the oxidized PAN fiber preform is in the female forming tool, wherein the forming comprises:

moving the first member at least partially into the die recess, the oxidized PAN fiber preform disposed between the first member and the female forming tool;

compressing the oxidized PAN fiber preform between the first member and the female forming tool; and

clamping the oxidized PAN fiber preform directly between a first grip strip and the female forming tool while the oxidized PAN fiber preform is being compressed between the first member and the female forming tool, the first grip strip is located at a first top surface of the female forming tool and disposed along a periphery of the oxidized PAN fiber preform;

removing the shaped body from the female forming tool;

moving the shaped body into a graphite fixture having a contoured shape corresponding to a shape of the die recess of the female forming tool and the first member;

performing a carbonization process on the shaped body at a temperature of greater than 1600° C. while the shaped body is in the graphite fixture;

depositing carbon on and within the shaped body via a chemical vapor infiltration process;

performing a heat treat at a temperature of greater than 1600° C.;

performing a second chemical vapor infiltration process on the shaped body; and

performing a second heat treat at a temperature of about 1200° C. to about 2600° C.

15 . The method of claim 14 , wherein the forming further comprises applying a sizing agent to the oxidized PAN fiber preform prior to the oxidized PAN fiber preform being formed into the shaped body, wherein the sizing agent comprises at least one of water, polyvinyl alcohol, modified starch, cellulose gum, carboxymethyl cellulose, modified wax, or acrylates.

16 . The method of claim 14 , wherein the forming further comprises applying at least one of heat or steam to the oxidized PAN fiber preform for a predetermined duration while the oxidized PAN fiber preform is held in compression in the die recess.

17 . The method of claim 16 , wherein the forming further comprises placing a dead weight onto the first member to hold the oxidized PAN fiber preform in compression in the die recess for the predetermined duration.

18 . The method of claim 17 , further comprising decreasing a gap between the first member and a second member with the dead weight during the predetermined duration.

19 . The method of claim 1 , wherein the second heat treat is performed for between about 4 hours and about 14 hours.

20 . The method of claim 1 , further comprising:

performing a third chemical vapor infiltration process on the shaped body; and

performing a third heat treat on the shaped body.

Assignments (6)

Continuity (2)

References Cited (104)