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GB2239214A - A sandwich structure and a method of manufacturing a sandwich structure - Google Patents

A sandwich structure and a method of manufacturing a sandwich structure Download PDF

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Publication number
GB2239214A
GB2239214A GB8929177A GB8929177A GB2239214A GB 2239214 A GB2239214 A GB 2239214A GB 8929177 A GB8929177 A GB 8929177A GB 8929177 A GB8929177 A GB 8929177A GB 2239214 A GB2239214 A GB 2239214A
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GB
United Kingdom
Prior art keywords
sandwich structure
sheets
sheet
matrix composite
fibres
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB8929177A
Other versions
GB2239214B (en
GB8929177D0 (en
Inventor
R David Malcolm Dawson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB8929177A priority Critical patent/GB2239214B/en
Publication of GB8929177D0 publication Critical patent/GB8929177D0/en
Publication of GB2239214A publication Critical patent/GB2239214A/en
Application granted granted Critical
Publication of GB2239214B publication Critical patent/GB2239214B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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    • B32B17/06Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/061Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of metal
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • C04B2237/50Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/70Forming laminates or joined articles comprising layers of a specific, unusual thickness
    • C04B2237/704Forming laminates or joined articles comprising layers of a specific, unusual thickness of one or more of the ceramic layers or articles
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/70Forming laminates or joined articles comprising layers of a specific, unusual thickness
    • C04B2237/706Forming laminates or joined articles comprising layers of a specific, unusual thickness of one or more of the metallic layers or articles

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

A sandwich structure (10) comprises a plurality of first sheets (12) and a plurality of second sheets (14) arranged alternately and bonded together. The first sheets (12) are thin metallic films of a metallic element, a metallic alloy or an intermetallic or of ceramic. The second sheets (14) are thin films of a glass matrix composite, a glass-ceramic matrix composite or a ceramic matrix composite. The second sheets (14) comprise a matrix (16) and unidirectional reinforcing fibres (18). The metallic films may be nickel or titanium, and the matrix composite may be anorthite or cordienite matrix reinforced with carbon, boron, silicon carbide, silicon nitride or alumina fibres. <IMAGE>

Description

A SANDWICH STRUCTURE AND A METHOD OF MANUFACTURING A SANDWICH STRUCTURE The present invention relates to sandwich structures and to a method of making sandwich structures comprising first and second sheets.
It is known in the prior art to have fibre reinforced composite metal matrix structures which comprise fibres embedded in a metal matrix. One method of manufacturing these metal matrix structures is by heating sheets of metal foil and fibres in an oven and then pressing the sheets together so that the fibres become embedded in the metal matrix as disclosed in British patent GB2168032A, and US patent 4746374. A further method sprays a metal onto a tape of fibres to embed the fibres in a metal matrix, as disclosed in US Patent 4782884.
It is also known in the prior art to have a sandwich structure which comprises a number of first sheets and a number of second sheets bonded together. The first sheets and the second sheets are different metallic sheets, and may have fibre embedded in a metal matrix, as disclosed in US Patent 4816347.
The present invention seeks to provide a novel sandwich structure, and a method of manufacturing the sandwich structure.
Accordingly the present invention provides a sandwich structure comprising at least one first sheet and at least one second sheet bonded together, the first sheet comprising a metallic sheet or a ceramic sheet, the second sheet comprising a glass matrix composite, a glass-ceramic matrix composite or a ceramic matrix composite, the second sheet including reinforcing fibres.
The first sheets and the second sheets may be arranged alternately.
The metallic sheet may comprise a metal matrix composite or an intermetallic.
The metallic sheet may comprise titanium or nickel.
The metal matrix composite may be a titanium metal matrix composite or a nickel metal matrix composite.
The intermetallic may comprise a titanium intermetallic or a nickel intermetallic.
The titanium intermetallic may be titanium aluminide.
The nickel intermetallic may be nickel aluminide.
The ceramic matrix may comprise anorthite or cordierite.
The glass matrix composite, the glass-ceramic matrix composite or the ceramic matrix composite may comprise carbon fibres, alumina fibres, silicon nitride fibres, silicon carbide fibres or other ceramic fibres.
The fibres may be arranged unidirectionally, crossplied or are woven.
The fibres may have diameters in the range 1 micrometer to 150 micrometers, and preferably have diameters in the range 7 micrometers to 20 micrometers.
The first sheet and the second sheet may have thicknesses in the range of 0.025 mm to 1 mm.
There may be up to twenty first and second sheets.
The present invention also provides a method of manufacturing a sandwich structure comprising stacking at least one first sheet and at least one second sheet, the first sheet comprising a metallic sheet, or a ceramic sheet, the second sheet comprising a glass matrix composite prepreg, a glass-ceramic matrix composite prepreg or a ceramic matrix composite prepreg, the second sheet including reinforcing fibres, applying heat and pressure to the stack of first and second sheets to bond the first and second sheets together.
The first and second sheets may be stacked alternately.
The application of heat and pressure may be hot isostatic pressing or hot pressing.
The stack of bonded first and second sheets may subsequently be superplastically formed.
The present invention will be more fully described by way of example, with reference to the accompanying drawings, in which: Figure 1 is an exploded perspective view of a sandwich structure according to the present invention,.
Figure 2 is an exploded perspective view of a second embodiment of a sandwich structure according to the present invention.
Figure 3 is an exploded perspective view of a third embodiment of a sandwich structure according to the present invention.
A sandwich structure 10 as shown in Figure 1, and comprises a plurality of first sheets 12 and a plurality of second sheets 14 arranged alternately. The first sheets 12 are metallic, and the second sheets 14 are glass matrix composites, glass-ceramic matrix composites or ceramic matrix composites. The second sheets 14 comprise a matrix material 16 in which a plurality of unidirectionally arranged fibres 18 are embedded.
The metallic first sheets are thin metallic foils or films, and the second sheets are also thin films. Several of the first sheets and second sheets are arranged alternately and stacked one on top of the other. The stack of first and second sheets is then placed in an oven and subjected to heat and pressure to consolidate the first and second sheets such that they bond together. The first and second sheets may be subjected to a hot isostatic pressuring process. As an example the first metallic sheets are O.lsm thick, and the second sheets are also O.lmm thick, the fibres have a diameter of the order of 7 micrometers to 20 micrometers. The second sheets are initially in a prepreg state of fibres loaded with a matrix in either a powder, sol-gel or fused form.
The metallic sheets 12 may be a metallic element, a metallic alloy or an intermetallic. For example the metallic sheet may comprise titanium, nickel, titanium aluminide or nickel aluminide.
The second sheets 14 may be a glass matrix composite, a glass-ceramic matrix composite or a ceramic matrix composite. For example the ceramic matrix 16 may comprise aluminosilicates with various elements either crystalline or amorphous, e.g. cordierite or anorthite, and the glass matrix 16 may be a glass sold under the trade name Pyrex.
The fibres 18 for example may be carbon, boron, alumina, silicon nitride, silicon carbide or other ceramic fibres.
As an alternative to using metallic first sheets in the sandwich structure, it is also possible to use ceramic first sheets which are thin green ceramic films or foils.
The ceramic sheets may, for example, be silicon carbide, silicon nitride, alumina or other ceramic powder in an organic binder/carrier.
This sandwich structure has the fibres embedded in a glass matrix, a glass-ceramic matrix or a ceramic matrix, compared to the prior art which has the fibres embedded in a metallic matrix. This has the advantage that a greater range of fibres can be used as reinforcement with lower risk of reaction with the matrix compared to the case with a metallic matrix. It is usually necessary to apply a protective coating on the fibres embedded in a metallic matrix to reduce the risk of reaction. The use of relatively small diameter fibres allows complex geometries to be manufactured, by allowing curved sandwich structures with relatively small radii, and enables flanges and apertures to be made more easily in a sandwich structure.
The discontinuity in material properties between the metallic sheets or ceramic sheets and the glass matrix composite, glass-ceramic matrix composite or ceramic matrix composite provides a greater barrier to crack propagation in the sandwich structure, than does the difference in material properties between two different metallic sheets. Also components manufactured from the sandwich structure will have relatively low density compared to all metal components.
The use of sandwich structure of titanium, titanium aluminide, nickel or nickel aluminide and glass matrix composite, glass-ceramic matrix composite or ceramic matrix composite has a high specific stiffness and is suitable for use at relatively high temperatures in the range of 5000C to 8000C.
A second sandwich structure 20 is shown in Figure 2, and comprises a plurality of first sheets 22 and a plurality of second sheets 24 arranged alternately. The first sheets 22 are metallic matrix composites, and comprise a metallic matrix 26 in which a plurality of unidirectionally arranged fibres 28 are embedded. The second sheets 24 are glass matrix composites, glass-ceramic matrix composites or ceramic matrix composites and comprise a ,matrix material 30 in which a plurality of unidirectionally arranged fibres 32 are embedded.
The metallic matrix composite first sheets and the second sheets are thin foils or films, which are for example O.lmm thick. The diameter of the fibres is in the range 7 to 20 micrometers.
The metallic matrix composite 22 may be a metallic element matrix composite a metallic alloy matrix composite or an intermetallic matrix composite. For example the metallic matrix composite may comprise a titanium matrix composite or a nickel matrix composite, reinforced with suitable fibres for example alumina or silicon carbide.
The fibres may require a protective coating depending on the particular metallic matrix. For example alumina is suitable for use with a nickel matrix, but requires a coating for use with a titanium matrix.
The second sheets 24 may be a glass matrix composite, a glass-ceramic matrix composite or a ceramic matrix composite. For example the ceramic matrix may comprise cordierite or anorthite, and the glass matrix may comprise a glass sold under the trade name Pyrex. The fibres 32 for example may be carbon, boron, alumina, silicon nitride, silicon carbide or other ceramic fibres.
The sandwich structure in Figure 2 may be manufactured using the same process as for the sandwich structure in Figure 1.
A third sandwich structure 40 is shown in Figure 3, and comprises a plurality of first sheets 42 and a plurality of second sheets 44 arranged alternately. The first sheets 42 are metallic or ceramic, and the second sheets 44 are glass matrix composites, glass-ceramic matrix composites or ceramic matrix composites. The second sheets 44 comprise a matrix material 46 in which a plurality of crossplied or woven fibres 48,50 are embedded.
The metallic first sheets and the second sheets are again thin foils or films, which are for example O.lmm thick. The diameter of the fibres is in the range 7 microns to 20 microns.
The metallic sheets 42 may be a metallic element, a metallic alloy, an intermetallic, a metallic element matrix composite, a metallic alloy matrix composite, an intermetallic matrix composite or a ceramic materialas discussed with reference to Figures 1 and 2. The second sheet 44 may be a glass matrix composite, a glass-ceramic matrix composite or a ceramic matrix composite as discussed with reference to Figures 1 and 2, but differs in that the fibres are arranged such that there is a first set of fibres 48 arranged parallel to each other, and a second set of fibres 50 arranged parallel to each other.
The second set of fibres 50 are arranged to extent transversely to the first set of fibres 48, and as shown the two sets of fibres are arranged for example perpendicularly. The two sets of fibres may be crossplied or woven together.
The third sandwich structure is manufactured using the same process as for the sandwich structure in Figure 1.
The first and second sheets may have various thicknesses in the range of 0.025 - to 1 sm, and the fibres may have various diameters in the range of 1 micrometer to 150 micrometer.
The sandwich structures described are suitable for manufacturing aerofoil shapes, for example for blades for gas turbine engines, or for manufacturing casings for example for gas turbine engines. They may however be suitable for other applications.
The sandwich structures described may be formed into the desired shape during the manufacturing process by arranging the stack of sheets to be consolidated at high temperature and pressure by tooling. The tooling is of a suitable shape to define the desired finished shape for the sandwich structure. Alternatively the consolidated sandwich structure may be subsequently superplastically formed to a desired finished shape.
The invention is applicable to produce sandwich structures from any metallic or ceramic sheets and glass matrix composite, glass-ceramic matrix composite or ceramic matrix composite.
Although the present description has referred to stacking the first and second sheets alternately throughout the sandwich structure, it may be desirable to arrange the first and second sheets in any appropriate sequence, for example such that there are two or more first sheets adjacent to each other and/or two or more second sheets adjacent to each other to obtain particular characteristics for the sandwich structure.

Claims (26)

Clalms:-
1. A sandwich structure comprising at least one first sheet and at least one second sheet bonded together, the first sheet comprising a metallic sheet or a ceramic sheet, the second sheet comprising a glass matrix composite, a glass-ceramic matrix composite or a ceramic matrix composite, the second sheet including reinforcing fibres.
2. A sandwich structure as claimed in claim 1 in which the first sheets and the second sheets are arranged alternately.
3. A sandwich structure as claimed in claim 1 or claim 2 in which the metallic sheet comprises a metal matrix composite.
4. A sandwich structure as claimed in claim 1 or claim 2 in which the metallic sheet comprises an intermetallic.
5. A sandwich structure as claimed in claim 1 or claim 2 in which the metallic sheet comprises titanium or nickel.
6. A sandwich structure as claimed in claim 3 in which the metal matrix composite is a titanium metal matrix composite or a nickel metal matrix composite.
7. A sandwich structure as claimed in claim 4 in which the intermetallic comprises a titanium intermetallic or a nickel intermetallic.
8. A sandwich structure as claimed in claim 7 in which the titanium intermetallic is titanium aluminide.
9. A sandwich structure as claimed in claim 7 in which the nickel intermetallic is nickel aluminide.
10. A sandwich structure as claimed in claim 1 or claim 2 in which the first ceramic sheet comprises silicon carbide, silicon nitride or alumina.
11. A sandwich structure as claimed in any of claims 1 to 10 in which the ceramic matrix comprises an aluminosilicate.
12. A sandwich structure as claimed in claim 11 in which the ceramic matrix comprises anorthite or cordierite.
13. A sandwich structure as claimed in any of claims 1 to 12 in which the glass matrix composite, the glass-ceramic matrix composite or the ceramic matrix composite comprises carbon fibres, alumina fibres, silicon nitride fibres, silicon carbide fibres or other ceramic fibres.
14. A sandwich structure as claimed in any of claims 1 to 13 in which the fibres are arranged unidirectionally crossplied or are woven.
15. A sandwich structure as claimed in any of claims 1 to 13 in which the fibres have diameters in the range 1 micrometer to 150 micrometers.
16. A sandwich structure as claimed in any of claims 1 to 15 in which the fibres have diameters in the range 7 micrometers to 20 micrometers.
17. A sandwich structure as claimed in any of claims 1 to 16 in which the first sheet and the second sheet have thicknesses in the range 0.025 mm to 1 mm.
18. A sandwich structure as claimed in any of claims 1 to 17in which there are upto twenty first and second sheets.
19 A sandwich structure substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
20. A method of manufacturing a sandwich structure comprising stacking together at least one first sheet and at least one second sheet, the first sheet comprising a metallic sheet or a ceramic sheet, the second sheet comprising a glass matrix composite prepreg, a glass-ceramic matrix composite prepreg or a ceramic matrix composite prepreg, the second sheet including reinforcing fibres, applying heat and pressure to the stack of first and second sheets to bond the first and second sheets together.
21. A method as claimed in claim 20 in which the first sheets and second sheets are stacked alternately.
22. A method as claimed in claim 20 or claim 21 in which the application of heat and pressure is by hot isostatic pressing or hot pressing.
23. A method as claimed in claim 20, claim 21 or claim 22 in which the stack of bonded first and second sheets is subsequently superplastically formed.
24. A method as claimed in claim 20,21 or claim 22 in which the stack of first and second sheets are bonded together by a superplastic forming process.
25. A method of manufacturing a. sandwich structure substantially as hereinbefore described with reference to the accompanying drawings.
26. An aerofoil comprising a sandwich structure as claimed in any of claims 1 to 19.
GB8929177A 1989-12-23 1989-12-23 A sandwich structure and a method of manufacturing a sandwich structure Expired - Fee Related GB2239214B (en)

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GB2239214A true GB2239214A (en) 1991-06-26
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EP0477755A1 (en) * 1990-09-18 1992-04-01 Norton Company Composite ceramic structure and use of same in a bearing
GB2249592A (en) * 1990-07-20 1992-05-13 Gen Electric Composite airfoil blade.
EP0501729A1 (en) * 1991-02-28 1992-09-02 British Aerospace Public Limited Company Method of producing a glass ceramic component
EP0528131A1 (en) * 1991-08-21 1993-02-24 Sumitomo Electric Industries, Limited Fiber-reinforced composites having having continuously varied fibre density across the month of the base layer, and manufacturing method thereof
WO2000037252A2 (en) * 1998-12-22 2000-06-29 Steuler Fliesen Gmbh Composite plate and method for the production thereof
US6132542A (en) * 1995-06-29 2000-10-17 The Regents Of The University Of California Method of fabricating hybrid ceramic matrix composite laminates
EP1568486A1 (en) * 2004-02-26 2005-08-31 Gkss-Forschungszentrum Geesthacht Gmbh Method for manufacturing of workpieces or semifinished products containing titanium aluminide alloys and products made thereby
EP1726787A2 (en) * 2005-05-24 2006-11-29 Rolls-Royce plc Containment casing for an aircraft engine
GB2442112A (en) * 2006-09-25 2008-03-26 Gen Electric Gas turbine engine containment casing
EP2363274A1 (en) * 2010-03-04 2011-09-07 Rolls-Royce plc Process for manufacturing a layered composite component
WO2018005105A1 (en) * 2016-07-01 2018-01-04 General Electric Company Ceramic matrix composite articles having different localized properties and methods for forming same
CN110759730A (en) * 2018-07-25 2020-02-07 比亚迪股份有限公司 Preparation method of composite ceramic and composite ceramic
EP4524375A1 (en) * 2023-09-18 2025-03-19 Safran Aero Boosters Low-pressure compressor housing of an aircraft turbomachine

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GB2249592A (en) * 1990-07-20 1992-05-13 Gen Electric Composite airfoil blade.
EP0477755A1 (en) * 1990-09-18 1992-04-01 Norton Company Composite ceramic structure and use of same in a bearing
EP0501729A1 (en) * 1991-02-28 1992-09-02 British Aerospace Public Limited Company Method of producing a glass ceramic component
EP0528131A1 (en) * 1991-08-21 1993-02-24 Sumitomo Electric Industries, Limited Fiber-reinforced composites having having continuously varied fibre density across the month of the base layer, and manufacturing method thereof
US5354398A (en) * 1991-08-21 1994-10-11 Sumitomo Electric Industries, Ltd. Method of manufacturing fiber-reinforced composites having a gradient function
US6132542A (en) * 1995-06-29 2000-10-17 The Regents Of The University Of California Method of fabricating hybrid ceramic matrix composite laminates
WO2000037252A2 (en) * 1998-12-22 2000-06-29 Steuler Fliesen Gmbh Composite plate and method for the production thereof
WO2000037252A3 (en) * 1998-12-22 2000-09-28 Steuler Fliesen Gmbh Composite plate and method for the production thereof
CN1660540B (en) * 2004-02-26 2010-09-01 Gkss-盖斯特哈赫特研究中心有限责任公司 Process for producing components or semi-finished products which contain only titanium aluminide alloys
EP1568486A1 (en) * 2004-02-26 2005-08-31 Gkss-Forschungszentrum Geesthacht Gmbh Method for manufacturing of workpieces or semifinished products containing titanium aluminide alloys and products made thereby
US7870670B2 (en) 2004-02-26 2011-01-18 Gkss-Forschungszentrum Geesthacht Gmbh Process including intermetallic titanium aluminide alloys
EP1726787A3 (en) * 2005-05-24 2012-07-18 Rolls-Royce plc Containment casing for an aircraft engine
EP1726787A2 (en) * 2005-05-24 2006-11-29 Rolls-Royce plc Containment casing for an aircraft engine
JP2008082332A (en) * 2006-09-25 2008-04-10 General Electric Co <Ge> Blade containment system for gas turbine engine
GB2442112A (en) * 2006-09-25 2008-03-26 Gen Electric Gas turbine engine containment casing
EP2363274A1 (en) * 2010-03-04 2011-09-07 Rolls-Royce plc Process for manufacturing a layered composite component
WO2018005105A1 (en) * 2016-07-01 2018-01-04 General Electric Company Ceramic matrix composite articles having different localized properties and methods for forming same
CN109415273A (en) * 2016-07-01 2019-03-01 通用电气公司 Ceramic matrix composite product with different local characteristics and the method for forming it
JP2019525882A (en) * 2016-07-01 2019-09-12 ゼネラル・エレクトリック・カンパニイ Ceramic matrix composite articles having different local properties and methods for forming the same
JP2022031308A (en) * 2016-07-01 2022-02-18 ゼネラル・エレクトリック・カンパニイ Ceramic matrix composite articles having different localized properties and methods for forming the same
US11383494B2 (en) 2016-07-01 2022-07-12 General Electric Company Ceramic matrix composite articles having different localized properties and methods for forming same
US11890836B2 (en) 2016-07-01 2024-02-06 General Electric Company Ceramic matrix composite articles having different localized properties and methods for forming same
CN110759730A (en) * 2018-07-25 2020-02-07 比亚迪股份有限公司 Preparation method of composite ceramic and composite ceramic
EP4524375A1 (en) * 2023-09-18 2025-03-19 Safran Aero Boosters Low-pressure compressor housing of an aircraft turbomachine

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