Abstract: The integral layer provides a ductile interface for attachment locations of a turbine engine component where a metallic surface is adjacent the attachment location. The ductile layer provides a favorable load distribution through the composite at the attachment location, and eliminates the need for a metallic shim.

Abstract: The present invention is ceramic matrix composite gas turbine engine component comprising a plurality of cured ceramic matrix composite plies, each ply comprising ceramic fiber tows, each ceramic fiber tow comprising a plurality of ceramic fibers, the tows in each ply lying adjacent to one another such that each ply has a unidirectional orientation. The component further comprises a layer of a coating on the ceramic fibers. The component further comprises a ceramic matrix material lying in interstitial regions between the fibers and tows of each ply and the interstitial region between the plurality of plies, wherein at least a portion of the component is no greater than about 0.021 inch thick. The present invention is also a method for making such a ceramic matrix composite component.

Abstract: The present invention is ceramic matrix composite gas turbine engine component comprising a plurality of cured ceramic matrix composite plies, each ply comprising ceramic fiber tows, each ceramic fiber tow comprising a plurality of ceramic fibers, the tows in each ply lying adjacent to one another such that each ply has a unidirectional orientation. The component further comprises a layer of a coating on the ceramic fibers. The component further comprises a ceramic matrix material lying in interstitial regions between the fibers and tows of each ply and the interstitial region between the plurality of plies, wherein at least a portion of the component is no greater than about 0.021 inch thick. The present invention is also a method for making such a ceramic matrix composite component.

Abstract: Thin plies used to manufacture components having changes in contour and changes in thickness and in fabricating thin cross-sections utilizing scrims. A scrim is applied to the surface of a thin, high temperature CMC prepreg ply. The scrim assists in maintaining the integrity of the thin ply during handling and lay-up operations thereby preventing damage to the thin plies and the lay-up. The scrim is a thin supportive layer applied to the surface of a thin prepreg to improve its handling characteristics, such as by preventing wrinkling. The scrim can be a coarse or fine mesh of thin or heavy fiber applied as a reinforcement. The scrim can be a temporary removable structure or can be incorporated into the component as part of the thin ply. The structure and composition of the scrim will be dependent upon whether the scrim is a temporary removable structure or whether it is incorporated permanently into the component.

Abstract: An inseparable assembly includes a body having a first surface and a second surface. The body includes an oxide-based ceramic matrix composite material having a first predetermined ductility. The assembly further includes a crack extending through the body between the first surface and the second surface, and a patch bonded to at least one of the first surface and the second surface overlapping at least a portion of an edge of the crack. The patch includes a second material having a second predetermined ductility that is greater than the first ductility.

Abstract: An inseparable assembly includes a body having a plurality of plies stacked in face to face relation and bonded together, wherein each of the plurality of plies includes a ceramic matrix composite material having a first predetermined ductility. The assembly further includes a reinforcement including a metallic wire mesh bonded to said body so that at least a portion of the metallic wire mesh is positioned between two adjacent plies in the body. The metallic wire mesh has a second predetermined ductility greater than the first ductility.

Abstract: A turbine airfoil includes at least one spar arrangement having a length less than an associated turbine airfoil length. During operation, the turbine airfoil has an outer skin surface which operates at a substantially higher temperature than that of an internal supporting parted spar arrangement. The parted spar arrangement permits the turbine airfoil outer skin surface to thermally expand between spar arrangements, thus preventing self-constraining thermal stresses from forming within the spar arrangement or the airfoil skin surfaces.

Abstract: A gripping system for use in uniaxial testing of test specimens at elevated temperatures, typically above 900.degree.-1000.degree. F. The uniaxial mechanical testing is typically tensile testing conducted on high temperature engineering materials which operate under severe conditions at elevated temperatures. The gripping system includes a gripping element having a first section adapted to contact the test specimen wherein a heater is received in the second section for heating the gripping surface. The heater is designed to heat the gripping surface and the test specimen to the desired temperature.