Abstract: Embodiments of the disclosure relate to the aligning of a melting beam source in an additive manufacturing (AM) system. Methods of the disclosure may include forming a first test article and a second test article of different shapes on a build plate. The method further includes measuring a vertical scale, vertical alignment, horizontal scale, and an alignment of the melting beam source using the first and second test articles. The method includes determining whether one of the vertical scale, the vertical alignment, the horizontal scale, or the horizontal alignment of the melting beam source is not within a corresponding tolerance of a target specification. If at least one of the vertical scale, the vertical alignment, the horizontal scale, or the horizontal alignment is within the corresponding tolerance, the method includes adjusting the melting beam source of the AM system to align the melting beam source to yield the target specification.

Abstract: Systems and methods for infiltrating porous ceramic matrix composite (CMC) preforms to form CMC articles are disclosed. One method may include positioning the porous CMC preform in an opening of a die set for an infiltration system, and flowing a molten densifier over the porous CMC preform in a first flow direction to infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform. The method may also include flowing the molten densifier over the porous CMC preform in a second flow direction, distinct from the first flow direction, to infiltrate the plurality of voids formed between each of the plurality of ply stacks of the CMC preform. The second flow direction may be substantially parallel to a predetermined, unidirectional material orientation of at least one ply stack of the plurality of ply stacks of the CMC preform.

Abstract: A method of manufacturing a ceramic matrix composite (CMC) turbine nozzle shell is provided. The method includes: assembling a primary outer nozzle platform, a primary inner nozzle platform, a core and trailing edge preform, and an airfoil-shaped body; joining the primary outer nozzle platform to a secondary outer nozzle platform of the airfoil-shaped body; and joining the primary inner nozzle platform to a secondary inner nozzle platform of the airfoil-shaped body. Composite plies circumferentially surround the airfoil-shaped body, and their longitudinal edges are cut into fingers that are folded down. The fingers are interleaved between secondary platform plies to form the secondary outer and inner nozzle platforms.

Abstract: Various embodiments include methods for densifying a melt infiltrated ceramic matrix composite (CMC) article, and a densified melt infiltrated CMC article formed thereby. Particular embodiments include a method including: providing a porous CMC preform within a first region of a casting apparatus; providing a molten densifier within a pressure head area of a second region of the casting apparatus, the first and second regions being operably connected and the molten densifier including at least one source of silicon; and applying a first pressure to the molten densifier within the pressure head, thereby infiltrating voids within the porous CMC preform with the molten densifier and forming a densified melt infiltrated CMC article.

Abstract: A ceramic matrix composite turbine nozzle includes a primary outer nozzle platform; a primary inner nozzle platform; and an airfoil-shaped body extending between the primary inner and primary outer nozzle platforms. The body includes core plies defining a cavity; composite wrap plies circumscribing the core plies and defining an airfoil shape; a secondary outer nozzle platform in contact with the primary outer nozzle platform; and a secondary inner nozzle platform in contact with the primary inner nozzle platform. Each composite wrap ply has two layers of unidirectional fibers oriented transverse to each other and has first and second longitudinal edges. The first and second longitudinal edges are cut into fingers, which are folded in a transverse direction away from a turbine nozzle longitudinal axis and are interleaved between platform plies to define the secondary inner nozzle platform and the secondary outer nozzle platform.

Abstract: Systems and methods for infiltrating porous ceramic matrix composite (CMC) preforms to form CMC articles are disclosed. One method may include positioning the porous CMC preform in an opening of a die set for an infiltration system, and flowing a molten densifier over the porous CMC preform in a first flow direction to infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform. The method may also include flowing the molten densifier over the porous CMC preform in a second flow direction, distinct from the first flow direction, to infiltrate the plurality of voids formed between each of the plurality of ply stacks of the CMC preform. The second flow direction may be substantially parallel to a predetermined, unidirectional material orientation of at least one ply stack of the plurality of ply stacks of the CMC preform.

Abstract: Various embodiments include methods for densifying a melt infiltrated ceramic matrix composite (CMC) article, and a densified melt infiltrated CMC article formed thereby. Particular embodiments include a method including: providing a porous CMC preform within a first region of a casting apparatus; providing a molten densifier within a pressure head area of a second region of the casting apparatus, the first and second regions being operably connected and the molten densifier including at least one source of silicon; and applying a first pressure to the molten densifier within the pressure head, thereby infiltrating voids within the porous CMC preform with the molten densifier and forming a densified melt infiltrated CMC article.

Abstract: A method of layering ceramic matrix composite (CMC) plies during a build of a component is disclosed. The method may include creating a plurality of CMC plies for creating the component. At least a first plurality of the plurality of the CMC plies each define both an outer portion and an inner portion of the component, each inner portion being defined within the outer portion by one or more openings in the respective CMC ply. The method may also include layering the plurality of CMC plies, and infiltrating the CMC plies with a binder to form the component. In one example, the component can be a turbine nozzle endwall.

Abstract: A ceramic matrix composite turbine nozzle includes a primary outer nozzle platform; a primary inner nozzle platform; and an airfoil-shaped body extending between the primary inner and primary outer nozzle platforms. The body includes core plies defining a cavity; composite wrap plies circumscribing the core plies and defining an airfoil shape; a secondary outer nozzle platform in contact with the primary outer nozzle platform; and a secondary inner nozzle platform in contact with the primary inner nozzle platform. Each composite wrap ply has two layers of unidirectional fibers oriented transverse to each other and has first and second longitudinal edges. The first and second longitudinal edges are cut into fingers, which are folded in a transverse direction away from a turbine nozzle longitudinal axis and are interleaved between platform plies to define the secondary inner nozzle platform and the secondary outer nozzle platform.

Abstract: A method of manufacturing a ceramic matrix composite (CMC) turbine nozzle shell is provided. The method includes: assembling a primary outer nozzle platform, a primary inner nozzle platform, a core and trailing edge preform, and an airfoil-shaped body; joining the primary outer nozzle platform to a secondary outer nozzle platform of the airfoil-shaped body; and joining the primary inner nozzle platform to a secondary inner nozzle platform of the airfoil-shaped body. Composite plies circumferentially surround the airfoil-shaped body, and their longitudinal edges are cut into fingers that are folded down. The fingers are interleaved between secondary platform plies to form the secondary outer and inner nozzle platforms.

Abstract: A process of producing a ceramic matrix composite component. The process includes positioning core plies on a mandrel. At least partially rigidizing the core plies to form a preform ceramic matrix composite arrangement defining a tip cavity and a hollow region. Ceramic matrix composite tip plies are positioned on the preform ceramic matrix composite arrangement and within the tip cavity. The ceramic matrix composite tip plies are densified to form a tip region of the composite component.

Abstract: A process of producing a ceramic matrix composite component. The process includes positioning core plies on a mandrel. At least partially rigidizing the core plies to form a preform ceramic matrix composite arrangement defining a tip cavity and a hollow region. Ceramic matrix composite tip plies are positioned on the preform ceramic matrix composite arrangement and within the tip cavity. The ceramic matrix composite tip plies are densified to form a tip region of the composite component.