The invention concerns an article (20) formed of a ceramic matrix composite structure having a plurality of ceramic fiber layers (22) and a binder material (24) interspersed throughout said layers. The ceramic matrix composite material may be sintered. The ceramic fiber layers undulate relative to one or more outer surfaces (38;40) of the article. Thus support features (48) within the article are able to share a load in use between a plurality of layers. The invention may be suited to engine components such as turbine seal segments in a gas turbine engine.

A rotor assembly is provided for a gas turbine engine. This rotor assembly includes a first rotor disk, a second rotor disk, a plurality of rotor blades and a plurality of disk mounts. The first rotor disk is configured to rotate about a rotational axis. The second rotor disk is configured to rotate about the rotational axis. The rotor blades are arranged circumferentially around the rotational axis. Each of the rotor blades is mounted to the first rotor disk and to the second rotor disk. The rotor blades include a first rotor blade. Each of the disk mounts connects the first rotor disk and the second rotor disk together. The disk mounts include a first disk mount that further supports the first rotor blade.

A method to produce a ceramic matrix composite with controlled surface characteristics includes: applying a scrim ply to a surface of a fiber preform, where the fiber preform includes silicon carbide fibers coated with boron nitride; infiltrating the fiber preform and the scrim ply with a slurry, thereby forming an impregnated ply on an impregnated fiber preform; infiltrating the impregnated fiber preform and the impregnated ply with a melt comprising silicon, and then cooling, thereby forming a ceramic matrix composite having a ceramic surface layer thereon, where the ceramic surface layer has a predetermined thickness and is devoid of boron; machining or grit blasting the ceramic surface layer to form an intermediate layer suitable for coating; and depositing an environmental barrier coating on the intermediate layer. Thus, a ceramic matrix composite coated with the environmental barrier coating is formed with the intermediate layer in between.

A brake component is disclosed. In various embodiments, the brake component includes a ceramic matrix composite (CMC) structure including a plurality of nominally dense plies, interleaved with a plurality of interlayers, wherein the plurality of nominally dense plies and the plurality of interlayers are bonded by at least one of a Field Assisted Sintering Technique (FAST), a Spark Plasma Sintering (SPS) process, or a localized heating process. In various embodiments, the brake component is a rotor disk or a stator disk.

A method for forming a passage in a ceramic matrix composite component incudes forming a core for a ceramic matrix composite component; embedding a hollow member into the core at a desired location for a passage in the ceramic matrix composite component; wrapping the core with a ceramic material; and inserting a rod through the hollow member and into the core.

The disclosure describes techniques for forming a surface layer of an article including a CMC using a cast. In some examples, the surface layer includes three-dimensional surface features, which may increase adhesion between the CMC and a coating on the CMC. In some examples, the surface layer may include excess material, with or without three-dimensional surface features, which is on the CMC. The excess material may be machined to remove some of the excess material and facilitate conforming the article to dimensional tolerances, e.g., for fitting the article to another component. The excess material may reduce a likelihood that the CMC (e.g., reinforcement material in the CMC) is damaged by the machining.

A gas turbine engine component includes a gas turbine engine component body formed of a ceramic matrix composite material having at least one fastener integrally formed with the gas turbine engine component body as a single-piece structure. The gas turbine engine component body initially comprises a rigidized preform structure formed from a polymer based material. The at least one fastener connects the gas turbine engine component body to an engine support structure.

The present disclosure discloses a hybrid woven fiber preform-reinforced composite material, including a fiber preform, a composite material interface and a matrix, where the fiber preform is a three-dimensional fabric hybrid woven by 2-5 high-performance inorganic fibers, and the matrix is selected from the group consisting of resin, light alloy, carbon and ceramic. A preparation method of the composite material includes: preparing ceramic slurry, fiber bundle impregnation treatment, fiber weaving, molding of three-dimensional overall structure preform, preform heat treatment, preparing interface and preparing matrix. The present disclosure improves the weaving performance of inorganic rigid fibers, and the prepared hybrid woven fiber preform-reinforced composite material has desirable integrity, high interlayer bonding strength, and is not easy to layer. Meanwhile, the present disclosure realizes the functions of wave transmission, wave-absorbing, high-temperature structural material, thermal insulation and thermal prevention through the combination of hybrid woven fibers.

A fiber-reinforced component for use in a gas turbine engine includes a fiber sleeve forming a cooling channel and a plurality of fiber plies enclosing the fiber sleeve, with the plurality of fiber plies forming first and second walls separated by the fiber sleeve. The fiber-reinforced component further includes a matrix material between fibers of the fiber sleeve and the plurality of fiber plies.

A seal assembly for a gas turbine engine according to an example of the present disclosure includes a seal that has a main body extending circumferentially between opposed mate faces. The main body has a sealing portion and an engagement portion extending outwardly from sealing portion along at least one of the mate faces. The main body has a core that has one or more core plies having a first fiber construction and arranged to establish an internal cavity. An overwrap has one or more overwrap plies having a second fiber construction and arranged to follow a perimeter of the one or more core plies to establish the engagement portion and the sealing portion, and the second fiber construction differs from the first fiber construction. The first fiber construction establishes a first target fiber volume fraction, the second fiber construction establishes a second target fiber volume fraction. A method of fabricating a seal for a gas turbine engine is also disclosed.