A fibrous preform (1) is produced, provided with a sandwich structure comprising an intermediate flexible core (4) and two outer fibrous frames (2, 3), respectively arranged on opposing outer faces of said flexible core (4) and assembled by sections of wire (8, 9) passing through said fibrous frames (2, 3), said preform (1) being impregnated with resin. Said preform is then hardened and the core (4) is removed, preferably by pre-densification with chemical vapour infiltration, and the structure produced is then densified with liquid-phase infiltration.

A method of processing a ceramic matrix composite (CMC) component includes extracting silicon from a surface region of the CMC component such that free silicon is present in the surface region at a reduced amount of about 5 vol. % or less. The extraction comprises contacting the surface region with a wicking medium comprising an element reactive with silicon. The extraction is carried out at an elevated temperature prior to assembling the CMC component with a metal component.

Flow path assemblies and methods for forming such flow path assemblies for gas turbine engines are provided. For example, a method for assembling an airfoil with a boundary structure to form a flow path assembly is provided. The method includes machining an opening into the boundary structure. The opening is sized to receive an airfoil or other component. The method also includes machining a cutout into the boundary structure proximate the opening. A locking feature is inserted into the cutout. When the airfoil is inserted into the opening, the locking feature interlocks the airfoil with the boundary structure. To seal the airfoil with the boundary structure, the airfoil is pressed against or into the boundary structure. When the airfoil is pressed, the locking feature is compressed such that a seal is formed between the airfoil and the boundary structure to seal the flow path assembly.

Vessels selected from crucibles, pans, open cups and saggars essentially comprising of two components, from which (A) one component being a ceramic matrix composite, and (B) the second component being from metal or alloy, and wherein component (A) is the inner one.

Hybrid composite materials including carbon nanotube sheets and flexible ceramic materials, and methods of making the same are provided herein. In one embodiment, a method of forming a hybrid composite material is provided, the method including: placing a layer of a first flexible ceramic composite on a lay-up tooling surface; applying a sheet of a pre-preg carbon fiber reinforced polymer on the flexible ceramic composite; curing the flexible ceramic composite and the pre-preg carbon fiber reinforced polymer sheet together to form a hybrid composite material; and removing the hybrid composite material from the lay-up tooling surface, wherein the first flexible ceramic composite comprises an exterior surface of the hybrid composite material.

A combination of a component and a composite, the composite having a) a PMC layer, and b) a tile layer comprising a plurality of Ox/Ox CMC tiles, each tile having: i) a central portion, ii) an outer portion and iii) one or more overlap joints formed by the overlapping of the outer portions of adjoining tiles so that hot gases entering a smooth top surface of the tile layer between abutting outer and central periphery segments must travel laterally between the overlapping outer portions of adjoining tiles to reach a top surface of the PMC layer. A method of heat shielding a component with a heat shielding composite comprising a) providing the composite and b) applying the composite to a surface of the component.

A method for forming a ceramic matrix composite (CMC) component with an internal cooling channel includes partially densifying a first fiber preform to form a portion of a final ceramic matrix volume, machining a first channel into a surface of the partially densified first fiber preform, covering the first channel with a fibrous member to form a near net shape fiber preform with an internal passage formed by the first channel and the fibrous member, and densifying the near net shape fiber preform.

A composite structure for use in tiling surfaces is disclosed. The composite structure can include a fiber matrix impregnated with a water-activated setting material. The composite structure can be wet and then compressed between a tile and an application surface. The composite structure can cure to provide a support surface for the tile.

A reinforced oxide-oxide CMC component for a gas turbine engine includes a composite body and a structural element embedded in the composite body, where the composite body comprises a 2D oxide-oxide composite and the structural element comprises a 3D oxide-oxide composite. The 2D oxide-oxide composite includes 2D woven or nonwoven oxide fibers in a first oxide matrix, and the 3D oxide-oxide composite includes 3D woven oxide fibers in a second oxide matrix. The first oxide matrix and the second oxide matrix may comprise the same or a different oxide.

Methods for repairing composite cylindrical components are provided. One exemplary method for repairing a cylindrical component defining an axial direction, a radial direction, and a circumferential direction includes removing a damaged region of the cylindrical component. A flange extending from a cylindrical body of the cylindrical component is included in the damaged region. One or more arc segments that extend along the circumferential direction are connected with the existing cylindrical component. At least one of the arc segments includes a prefabricated flange. One or more plies are laid up to connect the arc segments with the existing cylindrical component to repair the damaged region of the cylindrical body and the prefabricated flange formed integrally with one of the arc segments replaces the damaged portion of the flange. Repaired cylindrical components are also provided.