US5222296A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of making a fibre reinforced metal component
Assignee: Rolls Royce PLC
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Filing: 1991-08-02
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Granted: 1993-06-29
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Expires: 2011-08-02
Abstract
Abstract A ceramic fibre reinforced metal rotor with integral rotor blades is manufactured using a continuous strip of unidirectional ceramic fibres in a metal matrix. The continuous strip of ceramic fibres in the metal matrix is cut into a plurality of separate pieces of predetermined length. The separate pieces of ceramic fibres in the metal matrix are arranged alternately in a spiral, with separate pieces of unreinforced metal matrix in adjacent abutting relationship to form a ring which has a plurality of laminations. The ring of laminations of metal matrix composite pieces and unreinforced metal matrix pieces are arranged between an inner and an outer metal ring to form an assembly. The assembly is consolidated by hot isostatic pressing using radially applied pressure. The separate pieces of metal matrix composite provide compliance to reduce breaking or buckling of the fibres, and the pieces of unreinforced metal matrix prevents damage spreading between laminations.
Inventors
- 👤 Phillip J. Doorbar
- 👤 Ian D. A. Sudds
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 10:10
CPC Classifications
C; C22; C22C; C22C47/00; C22C47/02; C22C47/06; C22C47/062; C22C47/064; B; B23; B23P; B23P15/00; B23P15/006; C22C47/068; C22C47/20; F; F01; F01D; F01D5/00; F01D5/02; F01D5/12; F01D5/28; F01D5/282; F01D5/34; B22; B22F; B22F2998/00; B22F2998/10; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49316; Y10T29/4932; Y10T29/49321; Y10T29/49323; Y10T29/49325; Y10T29/49801
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
218 words
A method of manufacturing a fiber reinforced metal component comprising the steps of: first arranging a plurality of separate pieces of metal matrix composite and a plurality of separate pieces of unreinforced metal matrix alternately in adjacent abutting relationship to form at least one laminate, the pieces of metal matrix composite having a plurality of unidirectionally arranged fibers in a metal matrix and the fibers of each piece of metal matrix composite extending in substantially the same direction, each piece of metal matrix composite having a first end and a second end, the fibers in each piece of metal matrix composite extending between the first end and the second end of the piece of metal matrix composite, the step of first arranging further including the step of arranging the pieces of metal matrix composite and the pieces of unreinforced metal matrix such that at least one of the first and second ends of each piece of metal matrix composite is in abutting relationship within an adjacent piece of unreinforced metal matrix; second arranging the at least one laminate between a first metal member and a second metal member to form an assembly; and consolidating the assembly to bond the first metal member, the at least one laminate, and the second metal member to form a unitary composite component.
Claim 2
Independent Claim
218 words
A method of manufacturing a fiber reinforced metal component comprising the steps of: first arranging a plurality of separate pieces of metal matrix composite and a plurality of separate pieces of unreinforced metal matrix alternately in adjacent abutting relationship to form at least one laminate, the pieces of metal matrix composite having a plurality of unidirectionally arranged fibers in a metal matrix and the fibers of each piece of metal matrix composite extending in substantially the same direction, each piece of metal matrix composite having a first end and a second end, the fibers in each piece of metal matrix composite extending between the first end and the second end of the piece of metal matrix composite, the step of first arranging further including the step of arranging the pieces of metal matrix composite and the pieces of unreinforced metal matrix such that at least one of the first and second ends of each piece of metal matrix composite is in abutting relationship within an adjacent piece of unreinforced metal matrix; second arranging the at least one laminate between a first metal member and a second metal member to form an assembly; and consolidating the assembly to bond the first metal member, the at least one laminate, and the second metal member to form a unitary composite component.
Claim 3
Independent Claim
136 words
A method of manufacturing a fiber reinforced metal component comprising the steps of: first arranging at least one piece of metal matrix composite and at least one piece of unreinforced metal matrix alternately in adjacent abutting relationship to form at least one annular laminate, the at least one piece of metal matrix composite having a plurality of unidirectionally arranged fibers in a metal matrix and the fibers of the at least one piece of metal matrix composite extending in substantially the same direction; second arranging the at least one annular laminate between a first annular metal member and a second annular metal member to form an assembly; and consolidating the assembly to bond the first annular metal member, the at least one annular laminate, and the second annular metal member to form a unitary composite component.
Claim 4
Independent Claim
136 words
A method of manufacturing a fiber reinforced metal component comprising the steps of: first arranging at least one piece of metal matrix composite and at least one piece of unreinforced metal matrix alternately in adjacent abutting relationship to form at least one annular laminate, the at least one piece of metal matrix composite having a plurality of unidirectionally arranged fibers in a metal matrix and the fibers of the at least one piece of metal matrix composite extending in substantially the same direction; second arranging the at least one annular laminate between a first annular metal member and a second annular metal member to form an assembly; and consolidating the assembly to bond the first annular metal member, the at least one annular laminate, and the second annular metal member to form a unitary composite component.
Claim 5
Dependent Claim
43 words
A method as claimed in claim 2, wherein the first arranging step includes arranging the metal matrix composite which comprises a matrix of titanium, titanium aluminide, an alloy of titanium or any suitable metal, alloy or intermetallic which is capable of being bonded.
Claim 6
Dependent Claim
46 words
A method as claimed in claim 2, wherein the step of first arranging includes the step of arranging a plurality of separate pieces of metal matrix composite and a plurality of pieces of unreinforced metal matrix in a spiral to form a plurality of annular laminates.
Claim 7
Dependent Claim
47 words
A method as claimed in claim 2, wherein the step of first arranging includes the step of arranging a plurality of separate pieces of metal matrix composite and a plurality of separate pieces of unreinforced metal matrix in concentric rings to form a plurality of annular laminates.
Claim 8
Dependent Claim
23 words
A method as claimed in claim 2, wherein the step of first arranging includes arranging pieces of metal matrix composite having equal lengths.
Claim 9
Dependent Claim
29 words
A method as claimed in claim 2, wherein the step of second arranging includes arranging the second annular metal member radially outwardly of the at least one annular laminate.
Claim 10
Dependent Claim
24 words
A method as claimed in claim 7, further comprising the step of welding at least one rotor blade onto the second annular metal member.
Claim 11
Dependent Claim
35 words
A method as claimed in claim 8, wherein the welding step includes one of the steps of friction welding and electron beam welding the at least one rotor blade onto the second annular metal member.
Claim 12
Dependent Claim
32 words
A method as claimed in claim 7, further comprising the step of machining the second annular metal member to form at least one rotor blade integral with the second annular metal member.
Claim 13
Dependent Claim
30 words
A method as claimed in claim 10, wherein the step of machining includes the step of electrochemically machining the second annular member to form the at least one rotor blade.
Claim 14
Dependent Claim
55 words
A method as claimed in claim 7, wherein the second arranging step includes the steps of: third arranging pieces of the metal matrix composite and pieces of the unreinforced metal matrix on an inner surface of the second annular metal member, and moving the first annular metal member coaxially into the second annular metal member.
Claim 15
Dependent Claim
47 words
A method as claimed in claim 12, wherein the step of third arranging includes arranging the second annular metal member which has a radially inwardly extending flange at one axial end to locate the pieces of metal matrix composite and the pieces of unreinforced metal matrix axially.
Claim 16
Dependent Claim
47 words
A method as claimed in claim 13, wherein the step of third arranging includes arranging the first annular metal member which has a radially outwardly extending flange at one axial end to locate the pieces of metal matrix composite and the pieces of unreinforced metal matrix axially.
Claim 17
Dependent Claim
53 words
A method as claimed in claim 2, wherein the first arranging step includes the step of securing pieces of metal matrix composite and pieces of unreinforced metal matrix to a continuous backing strip to allow the pieces of metal matrix composite and the pieces of unreinforced metal to be wound into a spiral.
Claim 18
Dependent Claim
20 words
A method as claimed in claim 15, wherein the securing is to a backing strip which comprises unreinforced metal matrix.
Claim 19
Dependent Claim
32 words
A method as claimed in claim 2, wherein the first arranging step includes arranging the metal matrix composite having fibers which comprise silicon carbide, silicon nitride, boron, alumina, or other suitable ceramic.
Claim 20
Dependent Claim
18 words
A method as claimed in claim 2, wherein the consolidating step comprises the step of hot isostatic pressing.
Claim 21
Dependent Claim
34 words
A method as claimed in claim 2, wherein the consolidating step comprises the step of differential hot expansion of the first annular metal member inside the second annular metallic member of suitably low expansion.
Claim 22
Dependent Claim
49 words
A method as claimed in claim 2, wherein the second arranging step includes arranging the first annular metal member and the second annular metal member each of which comprises titanium, titanium aluminide, an alloy of titanium or any suitable metal, alloy or intermetallic which is capable of being bonded.
Claim 23
Dependent Claim
27 words
A method as claimed in claim 15, wherein the securing is to a backing strip which comprises a plastic or other suitable material which is subsequently removed.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-06-28 | 1996-12-28 | 1997-06-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-06-28 | 2000-12-28 | 2001-06-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-06-28 | 2004-12-28 | 2005-06-29 | $7700.00 | Window Closed / Lapsed |