Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.

Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.

Abstract: Systems, methods and devices adapted to ease manufacture of composite articles (e.g., ceramic composite articles), particularly composite articles which include a hollow feature are disclosed. In one embodiment, a system includes: a consumable core formed to be disposed within an inner portion of a composite precursor, the consumable core adapted to convert into an infiltrant during a manufacturing process and infiltrate the composite precursor.

Abstract: A method and system are provided for elementally detecting variations in density. The method includes providing a computed tomography device, comprising a radiation source, a detector, and at least one grating between the radiation source and the detector, positioning the component between the radiation source and the detector, directing radiation from the radiation source to the detector to acquire information from the component, generating at least one phase contrast image and at least one dark field contrast image of the component corresponding to variations in density with the information from the component, correlating the variations in density to a foreign mass, and displaying foreign mass distribution within the component.

Abstract: A method and system are provided for elementally detecting variations in density. The method includes providing a computed tomography device, comprising a radiation source, a detector, and at least one grating between the radiation source and the detector, positioning the component between the radiation source and the detector, directing radiation from the radiation source to the detector to acquire information from the component, generating at least one phase contrast image and at least one dark field contrast image of the component corresponding to variations in density with the information from the component, correlating the variations in density to a foreign mass, and displaying foreign mass distribution within the component.

Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.

Abstract: Methods for repairing a turbine airfoil constructed from a CMC material are provided via filling a cavity located in the turbine airfoil with a ceramic paste (e.g., including a ceramic powder and a binder), heating the ceramic paste in the cavity to remove the binder, thereby forming a porous ceramic material, and adding a molten ceramic material to the porous ceramic material. The cavity can be defined in an airfoil of the turbine airfoil (e.g., on a tip or cap of the airfoil). Intermediates formed during the repair of a turbine airfoil are also provided. The intermediate can generally include an airfoil comprising a CMC material, a cavity defined in the airfoil, and a porous ceramic material filling the cavity.

Abstract: A method of forming a ceramic matrix composite (CMC) component, a CMC component and a tip member are provided. The method of form the CMC component includes providing a component preform having a first end, a second end, and a cavity, the cavity having a pre-determined shape and a first engagement surface. The method includes forming a tip member from a pre-consolidated composite material, the tip member having a second engagement surface generally conforming to the first engagement surface. The method includes directing the second engagement surface to the first engagement surface. The method includes consolidating the component preform and tip member. The ceramic matrix composite component is formed having a desired geometry and the tip member stays in place in the cavity during operation of the ceramic matrix composite component.

Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.

Abstract: In certain embodiments of the present disclosure a method for modifying a composite article is described. The method includes positioning a plug made from composite material at a site on the composite article. The method further includes rotating at least one of the plug and the article at a rate of speed sufficient to form an inertia bond between the plug and the site of the composite article. The plug and the site are engaged to effect an inertia bond therebetween.

Abstract: Systems, methods and devices adapted to ease manufacture of composite articles (e.g., ceramic composite articles), particularly composite articles which include a hollow feature are disclosed. In one embodiment, a system includes: a consumable core formed to be disposed within an inner portion of a composite precursor, the consumable core adapted to convert into an infiltrant during a manufacturing process and infiltrate the composite precursor.

Abstract: In certain embodiments of the present disclosure a method for modifying a composite article is described. The method includes positioning a plug made from composite material at a site on the composite article. The method further includes rotating at least one of the plug and the article at a rate of speed sufficient to form an inertia bond between the plug and the site of the composite article. The plug and the site are engaged to effect an inertia bond therebetween.

Abstract: Methods for repairing a turbine airfoil constructed from a CMC material are provided via filling a cavity located in the turbine airfoil with a ceramic paste (e.g., including a ceramic powder and a binder), heating the ceramic paste in the cavity to remove the binder, thereby forming a porous ceramic material, and adding a molten ceramic material to the porous ceramic material. The cavity can be defined in an airfoil of the turbine airfoil (e.g., on a tip or cap of the airfoil). Intermediates formed during the repair of a turbine airfoil are also provided. The intermediate can generally include an airfoil comprising a CMC material, a cavity defined in the airfoil, and a porous ceramic material filling the cavity.

Abstract: A ceramic casting shell mold having a pre-selected shape is described. It includes alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based mat of reinforcing material disposed in the alternate, repeating layers of coating material and stucco. The reinforcing material for the mat is usually made from a ceramic material, and includes fibers having a bi-directional orientation. A method for making a ceramic casting shell mold is also described, as well as articles cast from such a mold, e.g., superalloy articles.

Abstract: A ceramic casting shell mold having a pre-selected shape is described. The shell mold comprises repeating layers of a ceramic material which define its wall thickness and shape. At least one of the layers of ceramic material contains refractory whiskers which provide structural reinforcement to the shell mold. The whiskers are usually incorporated into a layer of the ceramic material which is disposed at a position off-center of the wall-thickness of the mold. A method for making a ceramic casting shell mold is also described, as are metal- or metal alloy components cast in these shell molds.