Method of forming a ceramic matrix composite and a ceramic matrix component

1. A method of forming a ceramic matrix composite component, the method comprising the steps in the order of:

providing a formed ceramic member; then

inserting a barrier layer into the formed ceramic member to contact the formed ceramic member, the barrier layer and the formed ceramic member defining a cavity on a first side of the barrier layer, and the barrier layer and the formed ceramic member defining an internal passage on a second side of the barrier layer opposite the first side; then

filling at least a portion of the cavity on the first side of the barrier layer with a ceramic foam, wherein the cavity serves as a mold such that the mold defines a shape of at least a portion of the ceramic foam; and then

processing the formed ceramic member and the ceramic foam to obtain the ceramic matrix composite component.

2. The method of claim 1 , wherein the step of processing includes infiltrating the formed ceramic member and the ceramic foam to obtain the ceramic matrix composite component.

3. The method of claim 2 , wherein the step of processing further includes the step, prior to the step of infiltrating, of evaporating resins from the ceramic foam.

4. The method of claim 2 , wherein the step of infiltrating includes infiltrating with a silicon boron material.

5. The method of claim 1 , wherein the barrier layer includes at least one tab member, wherein the at least one tab member is operable to adhere to the formed ceramic member.

6. The method of claim 1 , wherein the barrier layer includes a corrugated geometry comprising a plurality of crests defining part of the mold.

7. The method of claim 1 , further including a step of, after the step of processing, of machining the ceramic matrix composite component.

8. The method of claim 1 , wherein the ceramic foam includes a material selected from alumina, mullite, silica, zirconia, zircon, silicon carbon, silicon boron, and combinations thereof.

9. A method of forming a ceramic matrix composite blade comprising:

providing a partially cured ceramic matrix composite blade shell, wherein the partially cured ceramic matrix composite blade shell has a cavity and the partially cured ceramic matrix composite blade shell has at least one internal passage;

applying a barrier layer adjacent to the at least one internal passage in the cavity of the partially cured ceramic matrix composite blade shell;

filling at least a portion of the cavity with a ceramic foam, the ceramic foam being applied to the barrier layer and operable to form a tip member; and

processing the partially cured ceramic matrix composite blade shell and the tip member to form a ceramic matrix composite blade.

10. The method of claim 9 , wherein the step of processing includes infiltrating the partially cured ceramic matrix composite blade shell and tip member ceramic foam to obtain the ceramic matrix composite blade.

11. The method of claim 10 , wherein the step of processing further includes the step, prior to the step of melt infiltrating, of evaporating resins from the ceramic foam of the tip member.

12. The method of claim 9 , wherein the barrier layer includes at least one tab member, wherein the tab member adheres to the mold of the formed ceramic member.

13. The method of claim 9 , wherein the barrier layer has a corrugated geometry.

14. The method of claim 9 , further including a step of, after the step of processing, of machining the ceramic matrix composite component.

15. The method of claim 9 , wherein the ceramic foam includes a material selected from alumina, mullite, silica, zirconia, zircon, silicon carbon, silicon boron, and combinations thereof.

16. The method of claim 1 , wherein the ceramic matrix composite component comprises a gas turbine component.

17. The method of claim 16 , wherein the gas turbine component comprises a gas turbine blade.

18. The method of claim 1 , wherein the barrier layer prevents ceramic foam in the mold from filling the internal passage.

19. The method of claim 18 , wherein filling comprises spraying the ceramic foam.

20. A method of forming a ceramic matrix composite component comprising:

providing a formed ceramic member; then

inserting a barrier layer into the formed ceramic member, the barrier layer and the formed ceramic member defining a cavity on a first side of the barrier layer and an internal passage on a second side of the barrier layer opposite the first side; then

filling at least a portion of the cavity on the first side of the barrier layer with a ceramic foam, wherein the cavity serves as a mold such that the mold defines a shape of at least a portion of the ceramic foam; and then

infiltrating the formed ceramic member and the ceramic foam with a silicon boron material to obtain the ceramic matrix composite component.