ОБОЛОЧКА ЯДЕРНОГО ТОПЛИВА С ВЫСОКОЙ УДЕЛЬНОЙ ТЕПЛОПРОВОДНОСТЬЮ И СПОСОБ ЕЕ ПРОИЗВОДСТВА

Данное изобретение относится к оболочкам микротвэлов ядерного реактора. Оболочка полностью или частично изготовлена из композиционного материала с керамической матрицей, содержащей волокна карбида кремния (SiC) в качестве армирования матрицы и межфазный слой между матрицей и волокнами. Матрица содержит, по меньшей, мере один карбид, выбранный из карбида титана (TiC), карбида циркония (ZrC) или тройного карбида титана-кремния (TiSiC)Способ изготовления оболочки ядерного топлива включает, в частности, изготовление волоконной предварительной формы, нанесение на нее химической паровой инфильтрацией межфазового слоя, нанесение матрицы. Технический результат - надежное механическое удержание продуктов деления ядерного топлива внутри оболочки при облучении и температурах между 800°C и 1200°C, при этом обеспечивается оптимальный перенос тепловой энергии к теплоносителю. 2 н. и 13 з.п. ф-лы, 2 ил.

СПОСОБ ПОЛУЧЕНИЯ ДЕТАЛЕЙ ИЗ КОМПОЗИТНОГО МАТЕРИАЛА ПУТЕМ ПРОПИТКИ КОМПОЗИЦИЕЙ С НИЗКОЙ ТЕМПЕРАТУРОЙ ПЛАВЛЕНИЯ

COMPOSITION FOR THE PRODUCTION OF METAL OF COMPOSITE MATERIALS

KERAMISCHE MASSEN, VERFAHREN ZU DEREN HERSTELLUNG UND DEREN VERWENDUNG

CERAMIC MASSES, PROCEDURES FOR THEIR PRODUCTION AND THEIR USE

COMPOSITE MATERIALS WITH CERAMIC MATRIX ON BORON CARBIDE BASIS

COATED CERAMIC FILLER MATERIALS

Coated ceramic filler materials comprised of ceramic particles, fibers, whiskers, etc. having at least two substantially continuous coatings thereon are provided. The coatings are selected so that the interfacial shear strength between the ceramic filler material and the first coating, between coatings, or between the outer coating and the surrounding matrix material, are not equal so as to permit debonding and pull-out when fracture occurs. The resultant, multi-coated ceramic filler materials may be employed to provide ceramic matrix composites with increased fracture toughness. The ceramic filler materials are designed to be particularly compatible with ceramic matrices formed by directed oxidation of precursor metals.

ELONGATE ULTRA HARD PARTICLE REINFORCED ULTRA HARD MATERIALS AND CERAMICS, TOOLS AND PARTS INCORPORATING THE SAME, AND METHOD OF MAKING THE SAME

Ultra hard materials and ceramics reinforced with elongate ultra hard material particles and methods of forming the same are provided. These materials have improved toughness and damage tolerance and can be used on, or to form, tools such as cutting tools and various work pieces and parts.

FRICTION ELEMENT IN COMPOSITE CARBON/CARBON-SILICON CARBIDE MATERIAL AND METHOD FOR MANUFACTURING SAME

A friction element is made out of a composite material comprising carbon fiber reinforcement and a matrix which, at least in the vicinity of the or each friction face, comprises: a first phase in the vicinity of the reinforcing fibers and containing pyrolytic carbon obtained by chemical vapor infiltration; a refractory second phase of carbon or ceramic obtained at least in part by pyrolysis of a liquid precursor; and a silicon carbide phase obtained by siliciding, for example. At least in the vicinity of the or each friction face, the composite material is preferably constituted, by volume, at least as follows: 15% to 35% carbon fibers; 10% to 55% first matrix phase containing pyrolytic carbon; 2% to 30% second matrix phase of refractory material; and 10% to 35% silicon carbide. The invention is applicable in particular to braking for rail or road vehicles.

PROTETHI ELEMENT.

SHEATH OF NUCLEAR FUEL HAS HIGH THERMAL CONDUCTIVITY AND ITS MANUFACTORING PROCESS.

MANUFACTORING PROCESS Of a COMPOSITE MATERIAL PART THERMOSTRUCTURAL AND PART THUS OBTAINED

COMPOSITE MATERIAL PART HAVING A CERAMIC MATRIX, AND METHOD FOR MANUFACTURING SAME

In a composite material part having a ceramic matrix and including a fibrous reinforcement which is densified by a matrix consisting of a plurality of ceramic layers having a crack-diverting matrix interphase positioned between two adjacent ceramic matrix layers, the interphase (10) includes: a first phase (12) made of a material conducive to the diversion of a crack reaching the interphase according to a first propagation mode in the transverse direction through one of the two ceramic matrix layers adjacent to the interphase, such that the propagation of the crack continues according to a second propagation mode along the interphase; and a second phase consisting of discrete contact pads (14) that are distributed within the interphase and conducive to the diversion of the crack that propagates along the interphase according to the second propagation mode, such that the propagation of the crack is diverted and continues according to the first propagation mode through the other ceramic matrix ...

METHOD FOR MANUFACTURING A COMPLEXLY SHAPED COMPOSITE MATERIAL PART

A method of fabricating a complex part out of composite material including three-dimensional woven fiber reinforcement densified by a matrix, the method including three-dimensionally weaving a continuous fiber strip including a succession of fiber blanks for preforms of a plurality of parts that are to be fabricated; subsequently cutting individual fiber blanks out from the strip, each blank being a one-piece blank; shaping a cut-out blank to obtain a one-piece fiber preform having a shape that is close to the shape of a part that is to be fabricated; consolidating the preform in the desired shape; and densifying the consolidated preform by forming a matrix by chemical vapor infiltration.

COMPOSITE MATERIAL PART HAVING A CERAMIC MATRIX, AND METHOD FOR MANUFACTURING SAME

MULTILAYER COATING FOR OXIDATION PROTECTION

A coated fiber structure for use in a ceramic matrix composite comprises a fiber and a coating system applied to and circumscribing the fiber. The coating system comprises an interface coating layer in direct contact with the fiber, the interface coating layer comprising one of boron nitride and a boron-doped pyrocarbon, at least one intermediate layer extending coaxially with and in direct contact with the interface layer, the at least one intermediate layer comprising at least one of silicon and boron nitride, and an outer layer extending coaxially with and in direct contact with the interface layer. At least one of the interface coating layer, the at least one intermediate layer, and the outer layer comprises a metallic element.

СПОСОБ ПОЛУЧЕНИЯ ДЕТАЛЕЙ ИЗ КОМПОЗИТНОГО МАТЕРИАЛА ПУТЕМ ПРОПИТКИ КОМПОЗИЦИЕЙ С НИЗКОЙ ТЕМПЕРАТУРОЙ ПЛАВЛЕНИЯ

Изобретение относится к способу получения детали из композиционного материала, включающему этапы: получение скрепленной волокнистой заготовки, причем волокна заготовки являются углеродными или керамическими волокнами и покрыты граничной фазой; получение упрочненной и частично уплотненной волокнистой заготовки, причем частичное уплотнение включает образование первой матричной фазы на граничной фазе в результате химической пропитки из паровой фазы, и продолжение уплотнения волокнистой заготовки путем пропитки пропиточной композицией, содержащей по меньшей мере кремний и по меньшей мере один другой элемент, способный снижать температуру плавления пропиточной композиции до значения меньше или равного 1150°C. Пропиточная композиция кроме кремния включает 50-75 мас.% никеля или 89-98 мас.% германия. Технический результат изобретения – исключение разрушения волокон заготовки в процессе изготовления детали. 10 з.п. ф-лы, 1 ил.

СПОСОБ ИЗГОТОВЛЕНИЯ ДЕТАЛИ СЛОЖНОЙ ФОРМЫ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА

Изобретение относится к способу изготовления деталей сложной формы из композиционного материала. Согласно способу изготавливают посредством трехмерного тканья непрерывной волокнистой полосы, содержащей непрерывный ряд волокнистых заготовок преформ множества подлежащих изготовлению деталей. Отрезают от полосы индивидуальных волокнистых заготовок, при этом каждая заготовка представляет собой единую деталь и включает участки, расположенные вблизи зон отсоединения связей, образовавшихся в процессе тканья. Придают отрезанной заготовке формы с получением волокнистой преформы в виде единой детали, имеющей форму, близкую к форме подлежащей изготовлению детали, причем придание формы включает отгиб или загиб вышеуказанных участков, расположенных вблизи зон отсоединения связей. Упрочняют преформу в желаемой форме. Уплотняют упрочненную преформу путем формирования матрицы посредством химической инфильтрации газовой фазы. Изобретение обеспечивает повышение качества изготовления деталей сложной формы ...

КАРБИДОКРЕМНИЕВЫЙ ЭЛЕМЕНТ, АРМИРОВАННЫЙ НЕПРЕРЫВНЫМИ ВОЛОКНАМИ, СПОСОБ ЕГО ПРОИЗВОДСТВА И СТРУКТУРНЫЙ ЭЛЕМЕНТ ЯДЕРНОГО РЕАКТОРА

Изобретение относится к армированному непрерывными волокнами карбидокремниевому элементу, способу его производства и к структурному элементу ядерного реактора. Армированный непрерывными волокнами карбидокремниевый элемент имеет трубчатую форму и имеет первый слой композиционного материала, второй слой композиционного материала и промежуточный слой, расположенный между первым слоем и вторым. В первом слое композиционного материала непрерывные волокна карбида кремния объединены с матрицей карбида кремния. Во втором слое композиционного материала непрерывные волокна углерода объединены с матрицей карбида кремния. Промежуточный слой сформирован из цельного тела материала, выбранного из группы, состоящей из титаноалюминиевого карбида, ванадий-алюминиевого карбида и т.д. Первый слой композиционного материала и второй слой композиционного материала расположены пакетом. Изобретение позволяет улучшить механические свойства и устойчивость к средовым воздействиям карбидокремниевого элемента. 3 н.

LIGHT METAL MATRIX COMPOSITE MATERIALS REINFORCED SILICON CARBIDE FIBRES AND A METHOD FOR PRDUCING SAID COMPOSITE MATERIALS

CERAMIC COMPOSITE MATERIALS WITH UNIDIRECTIONAL ADJUSTMENT OF THE REINFORCEMENT FIBERS AND PROCEDURES FOR THEIR PRODUCTION

A METHOD OF MAKING A FIBER PREFORM FOR MANUFACTURING PARTS OF A COMPOSITE MATERIAL OF THE CARBON/CARBON TYPE INCORPORATING CERAMIC PARTICLES, AND PRODUCTS OBTAINED THEREBY

... ²²²One or more two-dimensional fiber fabrics of carbon or carbon precursor fibers ²are impregnated (58, 59) by a solution or a suspension capable of allowing a ²dispersion of discrete ceramic particles to remain in the fiber fabric, and a ²fiber preform (51) is made by superposing plies formed of two-dimensional ²fabric made of carbon or carbon precursor fibers, the plies being bonded to ²one another, and at least some of the plies being at least partially formed of ²a previously- impregnated two- dimensional fabric. The field of application is ²particularly that of friction parts made of C/C composite material with ²incorporated ceramic particles.² ...

COMPOSITE MATERIAL PART HAVING A CERAMIC MATRIX, AND METHOD FOR MANUFACTURING SAME

In a composite material part having a ceramic matrix and including a fibrous reinforcement which is densified by a matrix consisting of a plurality of ceramic layers having a crack-diverting matrix interphase positioned between two adjacent ceramic matrix layers, the interphase (10) includes: a first phase (12) made of a material conducive to the diversion of a crack reaching the interphase according to a first propagation mode in the transverse direction through one of the two ceramic matrix layers adjacent to the interphase, such that the propagation of the crack continues according to a second propagation mode along the interphase; and a second phase consisting of discrete contact pads (14) that are distributed within the interphase and conducive to the diversion of the crack that propagates along the interphase according to the second propagation mode, such that the propagation of the crack is diverted and continues according to the first propagation mode through the other ceramic matrix ...

A SELF-REINFORCED SILICON NITRIDE CERAMIC WITH CRYSTALLINE GRAIN BOUNDARY PHASE, AND A METHOD OF PREPARING THE SAME

... 2100957 9213812 PCTABS00014 A fully densified, self-reinforced silicon nitride ceramic body of high fracture toughness and high fracture strength is disclosed comprising (a) .beta.-silicon nitride in the form of whiskers having an average aspect ratio of at least 2.5, and (b) a crystalline grain boundary phase having an oxynitride apatite structure, as determined by X-ray crystallography. A process for preparing the above-identified silicon nitride body comprises hot-pressing a powder mixture containing silicon nitride; silica; a densification aid including strontium oxide; a conversion aid, such as, yttrium oxide; and a compound, such as, calcium oxide which enhances growth of .beta.-silicon nitride whiskers, under conditions such that densification and the in situ formation of .beta.-silicon nitride whiskers having a high aspect ratio occur, and thereafter annealing the densified composition for a time sufficient to produce a crystalline grain boundary phase having an oxynitride apatite ...

СПОСОБ ИЗГОТОВЛЕНИЯ ВОЛОКНИСТОЙ ЗАГОТОВКИ ДЛЯ ПРОИЗВОДСТВА ДЕТАЛЕЙ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА УГЛЕРОД-УГЛЕРОДНОГО ТИПА И ТОРМОЗНОЙ ДИСК ИЗ УГЛЕРОД-УГЛЕРОДНОГО КОМПОЗИЦИОННОГО МАТЕРИАЛА

Одну или более чем одну двухмерную волокнистую ткань из углеродных волокон или прекурсоров углеродных волокон импрегнируют (58, 59) раствором или суспензией и обеспечивают возможность дисперсии дискретных керамических частиц оставаться на волокнистой ткани; и изготовляют волокнистую заготовку (51) путем наложения слоев, сформированных из двухмерной ткани, изготовленной из углеродных волокон или прекурсоров углеродных волокон, причем слои соединяют друг с другом, и, по меньшей мере, некоторые из слоев, по крайней мере, частично сформированы из предварительно импрегнированной двухмерной ткани. Отраслью применения являются, в частности, трущиеся детали, изготовленные из С/С композиционного материала, включающего керамические частицы.

Fabrication of a composite material component with a ceramic matrix and reinforcing fibres using an interphase coating, notably for aeronautical and spatial structural components subjected to hot gases

Un revêtement d'interphase est formé par infiltration chimique en phase vapeur (CVI) sur les fibres constitutives d'une préforme fibreuse, le revêtement d'interphase comportant au moins une couche interne de défragilisation du matériau composite, au contact des fibres, et une couche externe d'adhérence avec la matrice céramique. La préforme fibreuse est ensuite maintenue dans sa forme avec les fibres munies du revêtement d'interphase, et consolidée par imprégnation par une composition liquide contenant un précurseur de céramique, et transformation du précurseur en une phase consolidante de matrice céramique. La préforme consolidée est ensuite densifiée par une phase complémentaire de matrice céramique. Aucun outillage de maintien n'est nécessaire pour la formation du revêtement d'interphase par CVI ou pour la densification après consolidation par voie liquide.

MANUFACTORING PROCESS OF COMPOSITE MATERIAL PARTS THERMOSTRUCTURAL

PART COATED WITH A SURFACE COATING AND ASSOCIATED METHODS

L'invention concerne une pièce en matériau composite comportant un renfort fibreux densifié par une matrice céramique, la pièce présentant une surface externe et étant caractérisée en ce qu'elle est revêtue sur au moins une partie de sa surface externe par un revêtement de surface sous forme solide comportant un alliage de silicium et de nickel présentant une teneur massique en silicium comprise entre 29% et 45 % ou un alliage de silicium et de cobalt.

INFILTRATION PROCESS OR CHEMICAL VAPOR DEPOSITION USING THE PRECURSOR CI2BNH2 TO FORM BORON NITRIDE

L'invention concerne un procédé de fabrication d'un matériau composite comprenant au moins l'étape suivante : - formation de nitrure de bore sur la surface d'un ou plusieurs fils en carbone ou en matériau céramique présents dans une enceinte réactionnelle, le nitrure de bore étant formé par infiltration ou dépôt chimique en phase vapeur à partir d'une phase gazeuse introduite dans l'enceinte réactionnelle comprenant, lors de son introduction dans l'enceinte réactionnelle, un composé réactif précurseur de nitrure de bore de formule Cl2BNH2.

Article and method for making complex shaped preform and silicon carbide composite by melt infiltration

Small diameter silicon carbide-containing fibers are provided in a bundle such as a fiber tow that can be formed into a structure where the radii of curvature is not limited to 10-20 inches. An aspect of this invention is directed to impregnating the bundles of fibers with the slurry composition to substantially coat the outside surface of an individual fiber within the bundle and to form a complex shaped preform with a mass of continuous fibers.

Method of producing a part from a thermostructural composite material and part thus obtained

Le procédé comprend : - la formation par infiltration chimique en phase gazeuse sur les fibres (30) d'une structure fibreuse en fibres réfractaires d'une première couche d'interphase continue (32) ayant une épaisseur au plus égale à 100 nanomètres, - l'imprégnation de la structure fibreuse par une composition de consolidation comportant une résine précurseur de carbone ou céramique, - la formation d'une préforme fibreuse consolidée par mise en forme de la structure fibreuse imprégnée et transformation de la résine en un résidu solide discontinu (34) en carbone ou céramique par pyrolyse, - la formation par infiltration chimique en phase gazeuse d'une deuxième couche d'interphase continue (36), et - la densification de la préforme par une matrice réfractaire (38). On préserve ainsi la capacité de déformation de la structure fibreuse pour obtenir une préforme fibreuse de forme complexe tout en garantissant la présence d'une interphase continue entre fibres et matrice.

ЭЛЕМЕНТ ТОРМОЗНОГО УСТРОЙСТВА ИЗ КОМПОЗИТНОГО МАТЕРИАЛА C/C-SIC И СПОСОБ ЕГО ИЗГОТОВЛЕНИЯ

Изобретение относится к композитным материалам C/C-SiC, то есть к материалам с основой из волокон углерода, усиленной композитной матрицей углерод - карбид кремния для элементов тормозов. Элемент тормозного устройства изготавливается из композитного материала, включающего в себя основу из волокон углерода и матрицу, которая вблизи рабочей трущейся поверхности или поверхностей включает в себя первую фазу из пироуглерода, окружающего волокна основы и получаемого химическим осаждением из газовой фазы, вторую жаропрочную фазу из углерода или керамики, получаемуюя за счет пиролиза предшественника в жидком состоянии, и фазу карбида кремния, получаемую путем силицирования. Композитный материал вблизи рабочей поверхности или поверхностей состоит по объему из волокон углерода 15 - 35%, фазы с пироуглеродом 10 - 55%, фазы жаропрочного материала 2 - 30%, карбида кремния 10 - 35%. Технический результат - создание элементов тормозных устройств, обладающих стабильной воспроизводимой эффективностью торможения ...

ДЕТАЛЬ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА С КЕРАМИЧЕСКОЙ МАТРИЦЕЙ И СПОСОБ ЕЕ ИЗГОТОВЛЕНИЯ

... 1. Деталь из композиционного материала с керамической матрицей, содержащая волокнистый каркас, уплотненный матрицей, образованной из множества керамических слоев с включением матричного межфазного слоя, отклоняющего трещины, расположенного между двумя смежными керамическими слоями матрицы, отличающаяся тем, что межфазный слой (10; 110; 210) включает:- первую фазу (12; 112; 211) из материала, способного содействовать отклонению трещины, которая достигла межфазного слоя согласно первому виду распространения в поперечном направлении через один из двух керамических слоев матрицы, смежных с межфазным слоем, таким образом, что распространение трещины продолжается согласно второму виду распространения вдоль межфазного слоя, и- вторую фазу, образованную дискретными контактными участками (14; 114; 214), распределенными в межфазном слое и способными содействовать отклонению трещины, которая распространяется вдоль межфазного слоя согласно второму виду распространения, таким образом, что распространение ...

ОБОЛОЧКА ЯДЕРНОГО ТОПИВА С ВЫСОКОЙ УДЕЛЬНОЙ ТЕПЛОПРОВОДНОСТЬЮ И СПОСОБ ЕЕ ПРОИЗВОДСТВА

... 1. Оболочка ядерного топлива, полностью или частично изготовленная из композиционного материала на керамической матрице, включающего карбид кремния SiC, волокна в качестве армирования для указанной матрицы и межфазовый слой, предусмотренный между указанной матрицей и указанными волокнами, при этом указанная матрица содержит, по меньшей мере, один карбид, выбранный из карбида титана TiC, карбида циркония ZrC или тройного карбида титана-кремния Ti3SiC2. ! 2. Оболочка ядерного топлива по п.1, где указанная матрица дополнительно содержит карбид кремния SiC. ! 3. Оболочка ядерного топлива по п.2, где указанный карбид кремния SiC составляет менее 25% по объему указанной матрицы. ! 4. Оболочка ядерного топлива по п.3, где указазнный карбид кремния SiC составляет менее 10% по объему указанной матрицы. ! 5. Оболочка ядерного топлива по п.3, где указанный карбид кремния SiC составляет между 5% и 15% по объему указанной матрицы. ! 6. Оболочка ядерного топлива по п.1, где указанная матрица имеет столбчатую ...

AMORPHE BORCARBIDBESCHICHTUNG

MIT KOHLENSTOFF- ODER KOHLENSTOFFBESCHICHTETEN FASERN VERSTÄRKTE HOCHTEMPERATURBESTÄNDIGE VERBUNDWERKSTOFFE, DIE EINE VERBESSERTE STABILITÄT GEGEN OXIDATION AUFWEISEN

Keramikmatrix-Verbundwerkstoff und Verfahren zur Herstellung desselben

FRICTION ELEMENT FROM CARBON/CARBON SILICON CARBIDE VERBUNDWERUSTOFF AND PROCEDURES FOR ITS PRODUCTION

METHOD FOR MANUFACTURING PART MADE OF COMPOSITE MATERIAL

L'invention concerne un procédé de fabrication d'une pièce en matériau composite comprenant les étapes suivantes : - formation d'une texture fibreuse (10) à partir de fibres réfracta ires, - première imprégnation de la texture fibreuse (10) avec une première barbotine (150) contenant des premières particules réfractaires (151), - élimination de la phase liquide (152) de la première barbotine (151) de manière à ne laisser subsister à l'intérieur de ladite texture que les premières particules réfractaires (151), - deuxième imprégnation de la texture fibreuse (20) avec une deuxième barbotine (160) contenant des deuxièmes particules réfractaires (161), - élimination de la phase liquide (162) de la deuxième barbotine (160) de manière à ne laisser subsister à l'intérieur de ladite texture que les deuxièmes particules réfractaires (161) et obtenir une préforme fibreuse (30) chargée avec les premières et deuxièmes particules réfractaires (151, 161), et - frittage des premières et deuxièmes particules ...

Composite material part having a ceramic matrix, and method for manufacturing same

CMC material components

METHOD OF MAKING A COMPOSITE MATERIAL PART

MANUFACTORING PROCESS OF COMPOSITE MATERIAL PART HAS CERAMIC MATRIX AND PART THUS OBTAINED

COVERED FIBRES

METHOD FOR PROCESSING SILICON CARBIDE FIBERS BY REACTIVE CHEMICAL VAPOR DEPOSITION

METHOD FOR MAKING A PART OF COMPOSITE MATERIAL WITH CERAMIC MATRIX AND RESULTING PART

The invention concerns a method whereby an intermediate phase coating is formed by chemical vapour infiltration (CVI) on the fibers constituting a fibrous preform, the intermediate phase coating comprising at least one internal embrittlement relief layer of the composite material, in contact with the fibers, and an external adherence layer with the ceramic matrix. The fibrous preform is then maintained in its shape with the fibers provided with an intermediate phase coating, and reinforced by being impregnated with a liquid composition containing a ceramic precursor, and transformation of the precursor into a reinforcing phase of ceramic matrix. The reinforced preform is then densified by a complementary ceramic matrix phase. No maintenance tools are required for forming the intermediate phase coating by CVI or for densifying after reinforcement by liquid process.

Carbon-containing metal matrix composite material having high thermal conductivity and method for producing the same

A carbon-containing metal matrix composite material and a method for producing the same are described, wherein the graphitized vapor grown carbon fibers (VGCF) on which a metal carbide film is formed via a sintering step, so as to improve the compounding quality and increase the content of the carbon material in the metal matrix, are dispersed uniformly in the metal matrix. The graphitized VGCF used in the present invention can be unidirectional VGCF or the VGCF having a three-dimensional linkage structure.

СПОСОБ ИЗГОТОВЛЕНИЯ ДЕТАЛИ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА

Изобретение относится к способу изготовления детали из термоструктурного композиционного материала, которая может быть использована в качестве лопатки газотурбинного двигателя. Формируют волокнистую структуру из огнеупорных волокон, осуществляют первую пропитку волокнистой структуры первым шликером, содержащим первые огнеупорные частицы, удаляют жидкую фазу из первого шликера, пропитавшего волокнистую структуру, чтобы внутри указанной структуры оставались только первые огнеупорные частицы. Осуществляют вторую пропитку волокнистой структуры вторым шликером, содержащим вторые огнеупорные частицы, с последующим удалением жидкой фазы. Осуществляют спекание первых и вторых огнеупорных частиц, присутствующих в волокнистой заготовке, чтобы сформировать огнеупорную матрицу. Огнеупорные частицы первого и второго шликера отличаются по размеру и/или по химической природе. Технический результат изобретения - получение детали из композиционного материала с высокой долей матрицы и с характеристиками, ...

СПОСОБ ИЗГОТОВЛЕНИЯ ВОЛОКНИСТОЙ ЗАГОТОВКИ ДЛЯ ПРОИЗВОДСТВА ДЕТАЛЕЙ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА УГЛЕРОД/УГЛЕРОДНОГО ТИПА, ВКЛЮЧАЮЩЕГО КЕРАМИЧЕСКИЕ ЧАСТИЦЫ, И ПРОДУКТЫ, ПОЛУЧЕННЫЕ ЭТИМ СПОСОБОМ

Изобретение относится к изготовлению деталей из углерод-углеродного композиционного материала для использования, например, в качестве дисков для тормозных авиационных систем. Одну или более чем одну двухмерную волокнистую ткань из углеродных волокон или прекурсоров углеродных волокон импрегнируют золь-гель раствором или коллоидной суспензией, обеспечивающими возможность дисперсии дискретных керамических частиц оставаться на волокнистой ткани. Золь-гель раствор содержит прекурсор оксида, а коллоидная суспензия - оксид, выбранный из группы: TiO2, ZrO2, HfO2, SiO2. Изготавливают волокнистую заготовку путем наложения слоев, сформованных из двухмерной ткани, изготовленной из углеродных волокон или прекурсоров углеродных волокон, причем, по меньшей мере, некоторые из слоев, по меньшей мере, частично сформованы из предварительно импрегнированной двухмерной ткани. Слои соединяют друг с другом и проводят термообработку при температуре 1400-1750°C, после чего волокнистую заготовку уплотняют углеродной ...

СПОСОБ ИЗГОТОВЛЕНИЯ ДЕТАЛИ СЛОЖНОЙ ФОРМЫ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА

... 1. Способ изготовления деталей сложной формы из композиционного материала, содержащего волокнистый каркас, полученный путем трехмерного тканья и уплотненный матрицей, включающий этапы:- изготовление посредством трехмерного тканья непрерывной волокнистой полосы, содержащей непрерывный ряд волокнистых заготовок преформ множества подлежащих изготовлению деталей,- последующее отрезание от полосы индивидуальных волокнистых заготовок, при этом каждая заготовка представляет собой единую деталь,- придание отрезанной заготовке формы с получением волокнистой преформы в виде единой детали, имеющей форму, близкую к форме подлежащей изготовлению детали,- упрочнение преформы в желаемой форме, и- уплотнение упрочненной преформы путем формирования матрицы посредством химической инфильтрации газовой фазы.2. Способ по п.1, отличающийся тем, что осуществляют поверхностную обработку волокон тканой волокнистой полосы, включающую по меньшей мере одну из следующих операций: удаление замасливания волокон и кислотная ...

Coated ceramic filler materials

The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) of reinforcement materials in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the matrix such that any desirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. Ceramic filler materials which serve as reinforcements may have a plurality of super-imposed coatings thereon, at least one of which coatings may function as a getterer. The coated materials may be useful as reinforcing materials in ceramic matrix composites to provide improved mechanical properties such as fracture toughness. The present invention also relates to improved composites which incorporate these materials, and ...

PROCEDURE FOR THE PRODUCTION OF A FIBER GATHERING MOLD FOR THE PRODUCTION OF PARTS FROM A COMPOSITE MATERIAL OF TYPE OF CARBON/CCARBON WITH CERAMIC(S) PARTICLES AND THEREBY RECEIVED PRODUCTS

NUCLEAR FUEL COVERING WITH HIGH HEAT CONDUCTIVITY AND PROCESS TO YOUR PRODUCTION

A SELF-REINFORCED SILICON NITRIDE CERAMIC WITH CRYSTALLINE GRAIN BOUNDARY PHASE, AND A METHOD OF PREPARING THE SAME

Multi-layer coatings for reinforcements in high temperature composites

A METHOD OF FABRICATING A CERAMIC MATRIX COMPOSITE MATERIAL PART, AND A PART OBTAINED THEREBY

... ²An interphase coating is formed by chemical vapor ²infiltration (CVI) on the fibers constituting a fiber ²preform, the interphase coating comprising at least an ²inner layer in contact with the fibers for embrittlement ²relief to the composite material, and an outer layer for ²bonding with the ceramic matrix. The fiber preform is ²then kept in its shape by the fibers provided with the ²interphase coating and is consolidated by being ²impregnated with a liquid composition containing a ²ceramic precursor, and by transforming the precursor into ²a ceramic matrix consolidation phase. The consolidated ²preform is then densified by an additional ceramic matrix ²phase. No support tooling is needed for forming the ²interphase coating by CVI or for densification after ²consolidation using the liquid technique.²² ...

RAPID CERAMIC MATRIX COMPOSITE PRODUCTION METHOD

A method of producing a ceramic matrix composite comprising: a) applying a fiber interface coating to the composite, b) coating the composite via chemical vapor infiltration, and c) infiltrating the composite with molten material, wherein the composite is not removed from a tool between steps (a), (b), and (c), wherein the fiber interface coating and the chemical vapor infiltration are forced flow processes, wherein the forced flow fiber interface coating applies a pressure gradient of about 0.005 to about 1.0 atm, wherein the coating is carbon, boron nitride, or silicon doped boron nitride, wherein the chemical vapor infiltration applies silicon carbide, silicon nitride carbide, boron carbide, or carbon as a coating, wherein the coating is about 0.1 [micro]m to about 15.0 [micro]m, wherein the ceramic matrix composite is a tool, wherein the molten material comprises an alloy, wherein the molten material comprises silicon carbide, carbon, or a ceramic particulate, wherein the composite ...

A METHOD OF MAKING A FIBER PREFORM FOR MANUFACTURING PARTS OF A COMPOSITE MATERIAL OF THE CARBON/CARBON TYPE INCORPORATING CERAMIC PARTICLES, AND PRODUCTS OBTAINED THEREBY

One or more two-dimensional fiber fabrics of carbon or carbon precursor fibers are impregnated (58, 59) by a solution or a suspension capable of allowing a dispersion of discrete ceramic particles to remain in the fiber fabric, and a fiber preform (51) is made by superposing plies formed of two-dimensional fabric made of carbon or carbon precursor fibers, the plies being bonded to one another, and at least some of the plies being at least partially formed of a previously- impregnated two- dimensional fabric. The field of application is particularly that of friction parts made of C/C composite material with incorporated ceramic particles.

METHOD FOR MAKING CERAMIC MATRIX COMPOSITE ARTICLES

A method of forming a composite article includes impregnating an inorganic fiber preform with a slurry composition. The slurry composition includes a particulate, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to immobilize the particulate and yield a gelled article, and substantially all solvent is removed from the gelled article to form a green composite article. The green composite article is then infiltrated with a molten infiltrant to form the composite article.

METHOD FOR MANUFACTURING A COMPLEXLY SHAPED COMPOSITE MATERIAL PART

The invention relates to a complexly shaped composite material part including a three-dimensional, weaved, fibrous reinforcement densified by a matrix, and manufactured through a method comprising the following steps of: - three-dimensionally weaving a continuous, fibrous strip including a series of fibrous blanks (200) made of preforms having a plurality of parts to manufacture; - then cutting individual fibrous blanks into the strip, each blank (200) being made of a single part; - shaping a cut blank to obtain a fibrous preform having a shape corresponding to that of a part to be manufactured; - setting the preform in the desired shape; and densifying the set preform through the formation of a matrix by gaseous-phase chemical infiltration.

Method for modifying composite articles

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.

PROCESS FOR THE MANUFACTURE OF HIGH TEMPERATURE TERMOSTABLE FIBRES

COMPOSITE MATERIAL PART HAS CERAMIC MATRIX AND PROCESS FOR SA MANUFACTURE.

CERAMIC MATTERS OF LOAD ENROBEES.

Des matières céramiques de charge (4) enrobées comprennent des particules, fibres, trichites et analogues en céramique portant au moins deux enrobages sensiblement continus. Ceux-ci sont choisis de façon que la résistance au cisaillement interfacial entre la charge et le premier enrobage, entre les enrobages ou entre l'enrobage extérieur et la matrice avoisinante (2) ne soit pas égale pour permettre un décollement et un arrachement lorsqu'il y a fracture. Les composites qui comprennent ces charges résistent à la fracture.

ALUMINIUM- ELLER ALUMINIUMLEGERINGKOMPOSIT ARMERAD MED KISELKARBIDFIBRER OCH SETT ATT FRAMSTELLA DENNA

A METHOD OF MAKING A FIBER PREFORM FOR MANUFACTURING PARTS OF A COMPOSITE MATERIAL OF THE CARBON/CARBON TYPE INCORPORATING CERAMIC PARTICLES, AND PRODUCTS OBTAINED THEREBY

One or more two-dimensional fiber fabrics of carbon or carbon precursor fibers are impregnated (58, 59) by a solution or a suspension capable of allowing a dispersion of discrete ceramic particles to remain in the fiber fabric, and a fiber preform (51) is made by superposing plies formed of two-dimensional fabric made of carbon or carbon precursor fibers, the plies being bonded to one another, and at least some of the plies being at least partially formed of a previously- impregnated two- dimensional fabric. The field of application is particularly that of friction parts made of C/C composite material with incorporated ceramic particles.

PART MADE OF CMC

The invention relates to a part made of a ceramic matrix composite comprising a fibrous reinforcement made of carbon or ceramic fibres, and a mainly ceramic sequenced matrix comprising first matrix layers made of a crack deviator alternating with second matrix layers made of a ceramic. An interphase coating is interposed between the fibres and the matrix, the interphase coating adhering to the fibres and to the matrix and being formed from at least one sequence consisting of a first elementary layer made of carbon, which is optionally doped with boron, surmounted with a second elementary layer made of a ceramic, the external elementary layer of the interphase coating being a ceramic layer the external surface of which is formed by ceramic grains the size of which essentially lies between 20 nanometres and 200 nanometres, with the presence of grains larger than 50 nanometres in size providing the external surface with a roughness ensuring mechanical bonding with the adjacent matrix phase ...

Continuous fiber reinforced composites and methods, apparatuses, and compositions for making the same

A process for continuous composite coextrusion comprising: (a) forming first a material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate in a manner such that the composition has a substantially cylindrical geometry and thus can be used as a substantially cylindrical feed rod; (b) forming a hole down the symmetrical axis of the feed rod; (c) inserting the start of a continuous spool of ceramic fiber, metal fiber or carbon fiber through the hole in the feed rod; (d) extruding the feed rod and spool simultaneously to form a continuous filament consisting of a green matrix material completely surrounding a dense fiber reinforcement and said filament having an average diameter that is less than the average diameter of the feed rod; and (e) depositing the continuous filament into a desired architecture which preferably is determined from specific loading conditions of the desired object and CAD design of the object to provide ...

METHOD AND ARTICLE FOR METAL VAPOR INFILTRATION OF CMC PARTS

A method comprises discharging from a metal vaporization device a vapor of a metal or a metal precursor to a chemical vapor infiltration device where the chemical vapor infiltration device is in fluid communication with the metal vaporization device. The chemical vapor infiltration device contains a preform containing ceramic fibers. The preform is infiltrated with a metallic coating or a coating of a metallic precursor along with a ceramic precursor coating. The metallic coating and/or the metallic precursor coating and the ceramic precursor coating are applied sequentially or simultaneously.

СПОСОБ ИЗГОТОВЛЕНИЯ ВОЛОКНИСТОЙ ЗАГОТОВКИ ДЛЯ ПРОИЗВОДСТВА ДЕТАЛЕЙ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА УГЛЕРОД/УГЛЕРОДНОГО ТИПА, ВКЛЮЧАЮЩЕГО КЕРАМИЧЕСКИЕ ЧАСТИЦЫ, И ПРОДУКТЫ, ПОЛУЧЕННЫЕ ЭТИМ СПОСОБОМ

... 1. Способ изготовления волокнистой заготовки из, по меньшей мере, одной двухмерной волокнистой ткани из углеродных волокон или прекурсоров углеродных волокон для производства детали из углерод-углеродного композиционного материала, включающий: а) импрегнирование одной или более чем одной двухмерной волокнистой ткани из углеродных волокон или прекурсоров углеродных волокон в растворе или суспензии, обеспечивающих возможность дисперсии дискретных керамических частиц оставаться на волокнистой ткани; и б) изготовление волокнистой заготовки посредством наложения слоев, образованных из трехмерной ткани из углеродных волокон или прекурсоров углеродных волокон, и соединения этих слоев вместе, причем, по меньшей мере, некоторые из слоев, по меньшей мере, частично образованы из двухмерной ткани, предварительно импрегнированной на стадии а). 2. Способ по п.1, отличающийся тем, что двухмерную волокнистую ткань импрегнируют посредством непрерывного пропускания ткани через ванну. 3. Способ по п.1, отличающийся ...

Siliziumcarbid-Verbundwerkstoff verstärkt mit Metallnitrid beschichteten Fasern

BORON CARBIDE BASED CERAMIC MATRIX COMPOSITES

The present invention is a composite material and process to produce same. That material comprises a fibrous structure which is initially predominantly coated with elemental carbon; that fibrous structure is then subsequently predominantly coated with at least one ceramic material, e.g., boron carbide, which is non-reactive with silicon. The composite material also comprises a silicon matrix which is continuous and predominantly surrounds the fibrous structure, whch has been initially predominantly coated with elemental carbon and subsequently predominantly coated with at least one ceramic material. The matrix which has a fine grain crystalline structure of predominantly 20 microns or less in size. The at least one ceramic material is discontinuous within that matrix. The fibrous material pulls out of the elemental carbon, which initially predominantly coats that fibrous structure, when the composite is subjected to fracture.

METHOD FOR MAKING CERAMIC MATRIX COMPOSITE ARTICLES

A method of forming a composite article may include impregnating an inorganic fiber porous preform with a first slurry composition. The slurry composition includes particles, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to substantially immobilize the particles and yield a gelled article. The method also includes impregnating the gelled article with a second solution that includes a high char-yielding component, and pyrolyzing the high char-yielding component to yield carbon and form a green composite article. The green composite article is then infiltrated with a molten metal or alloy infiltrant to form the composite article. The molten infiltrant reacts with carbon, and the final composite article may include less residual metal or alloy than a composite article formed without using the second solution.

AN ADDITIVE MANUFACTURING TECHNOLOGY FOR THE FABRICATION AND CHARACTERIZATION OF NUCLEAR REACTOR FUEL

Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.

PROCESS FOR FABRICATING COMPOSITE PARTS BY LOW MELTING POINT IMPREGNATION

L'invention concerne un procédé de fabrication de pièce en matériau composite, comprenant les étapes de : - réalisation d'une préforme fibreuse consolidée, les fibres de la préforme étant des fibres de carbone ou de céramique et étant revêtues d'une interphase, - obtention d'une préforme fibreuse consolidée et partiellement densifiée, la densification partielle comprenant la formation sur l'interphase d'une première phase de matrice obtenue par infiltration chimique en phase gazeuse, et - poursuite de la densification par infiltration de la préforme fibreuse avec une composition d'infiltration contenant au moins du silicium et au moins un autre élément apte à abaisser la température de fusion de la composition d'infiltration à une température inférieure ou égale à 1150°C.

COMPOSITION FOR MAKING METAL MATRIX COMPOSITES

In one embodiment, a composition (10) to be mixed with a molten metal to make a metal matrix composite, the composition characterized by: a ceramic reinforcing filler (12), the ceramic reinforcing filler not being wettable by molten aluminum and/or not being chemically stable in molten aluminum, the ceramic reinforcing filler being coated with a ceramic material, the ceramic material being wettable by and chemically stable in molten aluminum. In a related embodiment, a composition (20) to make a porous preform to be infiltrated by molten metal to make a metal matrix composite, the composition characterized by: a ceramic reinforcing filler (23), the ceramic reinforcing filler not being wettable by molten aluminum, the ceramic reinforcing filler being coated with a ceramic material (22) and optionally with a metal (21) such as nickel, the ceramic material being wettable by molten aluminum. The ceramic material can be coated on the ceramic reinforcing filler by a vacuum deposition technique ...

MULTI-LAYER COATINGS FOR REINFORCEMENTS IN HIGH TEMPERATURE COMPOSITES

SEP-3964 The subject invention relates to a coated reinforcement material comprising a SiC reinforcement having a coating of at least three layers, wherein the layers are alternately A-material layers of the general formula: AlxOyNz wherein x is up to about 60 atomic% of the coating; y is from about 20 atomic% to about 55 atomic% of the coating; and z is from about 5 atomic% to about 45 atomic% of the coating, with the proviso that x+y+z=100, and Bmaterial layers comprising a metal alloy, such that the first and last layers of the coating are A-material layers. The invention further relates to a high stength, high temperature performance composite containing the abovespecified coated reinforcement. AI4/Applns ...

MANUFACTORING PROCESS OF COMPOSITE MATERIAL PARTS THERMOSTRUCTURAL

Un procédé de fabrication de pièce en matériau composite thermostructural comprend la réalisation d'une préforme fibreuse formée de fils ou câbles, et imprégnée par une composition consolidante contenant un précurseur de carbone ou céramique, la transformation du précurseur en carbone ou céramique par pyrolyse et, ensuite, la densification de la préforme par infiltration chimique en phase gazeuse. On utilise une composition consolidante qui contient en outre des charges solides réfractaires sous forme de poudre de granulométrie moyenne inférieure à 200 nanomètres et qui laisse, après pyrolyse, une phase solide consolidante dans laquelle le carbone ou la céramique issu du précurseur occupe un volume représentant entre 3% et 10% du volume apparent de la préforme et les charges solides occupent un volume représentant entre 0,5% et 5% du volume apparent de la préforme.

CERAMIC MATRIX COMPOSITE CORROSION RESISTANT AND METHOD OF MANUFACTURE

Matériau composite (1) comprenant un renforcement par des fibres (10) et une matrice céramique dans laquelle les fibres revêtues d'une interphase (11) sont incluses, la dite matrice céramique étant caractérisée par le fait qu'elle comprend : - au moins une couche continue uniforme (13) d'un matériau constitué de bore et de carbone, ce dernier à une concentration comprise entre 0,4 et 8 % en pourcentage atomique ; - et au moins deux couches réfractaires (12), chacune constituée d'un à plusieurs composés sélectionnés parmi le groupe des carbures, siliciures et oxydes, couches réfractaires dont une (12a) est en contact avec l'interphase, et au moins une autre (12c) est plus éloignée des fibres que toute couche (13) constituée de bore et de carbone. Le procédé de fabrication du matériau composite (1) caractérisé en ce que la matrice céramique comporte plusieurs étapes de formation : - d'au moins une couche continue uniforme (13) d'un matériau constitué de bore et de carbone, ce dernier à une ...

CARBON FIBER CONTAINING CERAMIC PARTICLES

Small ceramic particles (e.g., of TiC) are incorporated into fibers. The ceramic particles enhance the friction and/or wear properties of a carbon-carbon composite article made with the impregnated or coated f ibers. The impregnated fibers can be, e.g., polyacrylonitrile (PAN) fibers, pitch f ibers, and other such fibers as are commonly employed in the manufacture of C-C friction materials. The impregnated f ibers can be used to make woven, nonwoven, or random fiber preforms or in other known preform types. Preferred products are brake discs and other components of braking systems. The particles may be included in the fibers by mixing them with the resin employed to make the fibers and/or by applying them to the surfaces of the fibers in a binder.

Fiber-containing composite

Fibrous material is coated with boron nitride and a silicon-wettable material, the coated fibrous material is admixed with an infiltration-promoting material which is at least partly elemental carbon and the mixture is formed into a preform which is infiltrated with a molten solution of boron and silicon producing a composite containing boron nitride coated fibrous material.

Consolidation and densification methods for fibrous monolith processing

Methods for consolidation and densification of fibrous monolith composite structures are provided. Consolidation and densification of two- and three-dimensional fibrous monolith components having complex geometries can be achieved by pressureless sintering. The fibrous monolith composites are formed from filaments having at least a first material composition generally surrounded by a second material composition. The composites are sintered at a pressure of no more than about 30 psi to provide consolidated and densified fibrous monolith composites.

Production of a combustion chamber made of composite material

A method for producing an annular combustion chamber of a turbojet using CMC. For this, a shaping tool with movable slides is used and said chamber is produced around the tool, thereby producing a fibrous preform of which the shape is consolidated by drape moulding on the tool and pyrolysis, which is then densified by CVI. Several slides have back drafts, at least one other of such slides having a draft or neither a draft nor a back draft. Then, the slides are removed in a predetermined order imposed by the back drafts and the relative positions of the slides.

METHOD FOR MAKING CERAMIC MATRIX COMPOSITE ARTICLES

A method of forming a composite article includes impregnating an inorganic fiber preform with a slurry composition. The slurry composition includes a particulate, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to immobilize the particulate and yield a gelled article, and substantially all solvent is removed from the gelled article to form a green composite article. The green composite article is then infiltrated with a molten infiltrant to form the composite article.

Method of making ceramic composite devices with unidirectionally aligned reinforcing fibers

Ceramic composite materials have unidirectional alignment of the reinforcing fibers. The ratio of the volume of the fiber strands of the reinforcing fibers to the volume of the matrix is at least 0.5. A process for their production involves initially coating the fiber strands or rovings of the reinforcing fibers with a sacrificial polymer. The coated fiber strands are processed with binder resins into unidirectionally reinforced CFK molded parts. The formed CFK bodies are carbonized to form CFC bodies. The CFC bodies are then silicized with liquid silicon. The liquid silicon diffuses into the pores formed in the CFC body and combines there at least partially with the carbon to form silicon carbide. The sacrificial polymer is pyrolized. The ceramic composite materials also can be used in fiber-reinforced ceramic structural parts.

ДЕТАЛЬ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА С КЕРАМИЧЕСКОЙ МАТРИЦЕЙ И СПОСОБ ЕЕ ИЗГОТОВЛЕНИЯ

Изобретение относится к производству конструктивных деталей, подвергающихся при эксплуатации воздействию высоких температур, и касается детали из композиционного материала с керамической матрицей и способа ее изготовления. Содержит волокнистый каркас, уплотненный матрицей, образованной из множества слоев из керамики с включением матричного межфазного слоя, отклоняющего трещины между двумя смежными керамическими слоями матрицы. Межфазный слой включает первую фазу из материала, способного содействовать отклонению трещины, которая достигла межфазного слоя согласно первому виду распространения в поперечном направлении через один из двух керамических слоев матрицы, смежных с межфазным слоем, таким образом, что распространение трещины продолжается согласно второму виду распространения вдоль межфазного слоя, и вторую фазу, образованную дискретными контактными участками, распределенными в межфазном слое и способными содействовать отклонению трещины, которая распространяется вдоль межфазного слоя ...

СПОСОБ ИЗГОТОВЛЕНИЯ ДЕТАЛИ ИЗ КОМПОЗИЦИОННОГО МАТЕРИАЛА

Inorganic Fibre Coating by Atomic Layer Deposition

A method of coating inorganic fibres by atomic layer depositions (ALD) is disclosed. Coating materials are deposited at low temperature and pressure with the sequential exposure of gaseous precursors. The fibre may be formed from carbon, metal, alumina, silica or semiconductor. The fibre may be surface-modified prior to coating. The coating may be a ceramic oxide, sulphide, nitride, phosphide, fluoride, carbide, phosphate, arsenide, selenide, telluride, a metal or a non-metal such as carbon, phosphorus or sulphur. The coatings formed may be smooth and homogenous on each fibre in a fibre bundle. The coated inorganic fibres can be used for reinforcing ceramic matrix composite, forming microelectrodes, as an optical fibre, or as a template for micro- andnano-tubes.

DENTAL CERAMICS CONTAINING THIN INORGANIC FIBRES

CERAMIC COMPOSITE MATERIAL FOR PRODUCING POROUS SURFACE LAYERS OF IMPLANTABLE BONE AND TEETH SUBSTITUTES

A ceramic composite material comprise a substantially homogeneous mixture containing a ceramic base substance and inorganic fibers in an amount of up to about 2 weight % base on the ceramic base substance in unprocessed powder form, the inorganic fibers having a thickness of not mere than about 600 .mu. and a melting temperature higher than the sintering temperature of the ceramic base substance; the fibers and base substance are selected such that the base substance in its molten conditions does not dissolve the fibers. The ceramic composite material of the invention is suitable for the direct production of porous surface layer of prosthetic elements which are at least partially implantable into the body, these being obtained through fixing the ceramic composite material at a temperature corresponding to the sintering temperature of the ceramic base substance.

REINFORCING FIBERS AND COMPOSITE MATERIALS REINFORCED WITH SAID FIBERS

A reinforcing inorganic fiber composed of an internal layer and a surface layer, wherein said internal layer is composed of an inorganic material containing silicon, either titanium or zirconium, carbon and oxygen which is (i) an amorphous material consisting substantially of Si, M, C and O, or (ii) an aggregate consisting substantially of ultrafine crystalline particles with a particle diameter of not more than 500 .ANG. of .beta.-SiC, MC, a solid solution of .beta.-SiC and MC and MC1-x, wherein M represents titanium or zirconium, and x is a number represented by 0 Подробнее

MELT INFILTRATION WITH SIGA AND/OR SIIN ALLOYS

Methods for forming a ceramic matrix composite (CMC) are generally provided. The method may include melt infiltrating a silicon mixture into a ceramic matrix composite preform, with the silicon mixture including SiGa, Siln, or a mixture thereof. The silicon mixture may include silicon metal in combination with SiGa, Siln, or the mixture thereof. Additionally, the silicon mixture may further include B within the SiGa, Siln, or the mixture thereof (e.g., in the form of SiBGa, SiBIn, or a mixture thereof).

Composite material part having a ceramic matrix, and method for manufacturing same

MATERIAL COMPONENT CMC

Composite ceramic materials, in particular for the realization of turbine blades to gas

Matériau de remplissage en céramique enrobé conçu de façon à être utilisé en tant que composant de renfort dans un composite comprenant une matrice de céramique formée par la réaction d'oxydation dirigée d'un métal précurseur fondu avec un oxydant et enrobant ledit matériau de remplissage caractérisé en ce que ce matériau comporte une pluralité de revêtements superposés constitués d'un premier revêtement en contact sensiblement continu avec ledit matériau de remplissage formant une première jonction de zone entre le matériau de remplissage et le premier revêtement, et d'un revêtement extérieur, en contact sensiblement continu avec le revêtement sous-jacent formant une seconde jonction de zone entre le revêtement extérieur et la matrice de céramique et en ce que la résistance au cisaillement de zone de l'une des trois jonctions de zone est faible par rapport aux deux autres jonctions de zone de manière à permettre un désassemblage du matériau de remplissage lors de l'application d'un effort ...

COMPOSITE MATERIAL PART HAS CERAMIC MATRIX AND PROCESS FOR SA MANUFACTURE.

Dans une pièce en matériau composite à matrice céramique comprenant un renfort fibreux densifié par une matrice formée de plusieurs couches en céramique avec interposition d'une interphase matricielle déviatrice de fissures entre deux couches de matrice en céramique voisines, l'interphase (10) comprend une première phase (12) en un matériau apte à favoriser la déviation d'une fissure qui parvient à l'interphase selon un premier mode de propagation en direction transversale à travers l'une des deux couches de matrice en céramique adjacentes à l'interphase, de sorte que la propagation de la fissure se poursuive selon un deuxième mode de propagation le long de l'interphase, et une deuxième phase formée de plots discrets (14) répartis dans l'interphase et apte à favoriser la déviation de la fissure qui se propage le long de l'interphase selon le deuxième mode de propagation, de sorte que la propagation de la fissure soit déviée et se poursuive selon le premier mode de propagation à travers ...

SHEATH OF NUCLEAR FUEL HAS HIGH THERMAL CONDUCTIVITY AND ITS MANUFACTORING PROCESS.

Gaine de combustible nucléaire, constituée en tout ou partie d'un matériau composite à matrice céramique comprenant des fibres de carbure de silicium SiC en tant que renfort de ladite matrice et une couche d'interphase disposée entre ladite matrice et lesdites fibres, ladite matrice comprenant au moins un carbure choisi parmi le carbure de titane TiC, le carbure de zirconium ZrC ou le carbure ternaire de silicium et de titane Ti3SiC2. Une telle gaine permet, sous irradiation et à des températures comprises en 800 °C et 1200 °C, de maintenir mécaniquement le combustible nucléaire au sein de la gaine tout en assurant la transmission optimale de l'énergie thermique vers le caloporteur. L'invention concerne également un procédé de fabrication de la gaine de combustible nucléaire.

MANUFACTORING PROCESS Of a MATERIAL PART COMPOSITIE THERMOSTRUCTURAL AND PART THUS OBTAINED

Le procédé comprend : - la formation par infiltration chimique en phase gazeuse sur les fibres (30) d'une structure fibreuse en fibres réfractaires d'une première couche d'interphase (32) ayant une épaisseur au plus égale à 100 nanomètres, - l'imprégnation de la structure fibreuse par une composition de consolidation comportant une résine précurseur de carbone ou céramique, - la formation d'une préforme fibreuse consolidée par mise en forme de la structure fibreuse imprégnée et transformation de la résine en un résidu solide (34) en carbone ou céramique par pyrolyse, - la formation par infiltration chimique en phase gazeuse d'une deuxième couche d'interphase (36), et - la densification de la préforme par une matrice réfractaire (38). On préserve ainsi la capacité de déformation de la structure fibreuse pour obtenir une préforme fibreuse de forme complexe tout en garantissant la présence d'une interphase continue entre fibres et matrice.

METHOD OF PRODUCING A PART COATED WITH A SURFACE COATING COMPRISING AN ALLOY

Method for manufacturing high-density fiber reinforced ceramic composite materials

Disclosed herein is a method of manufacturing a high-density fiber reinforced ceramic composite material, including the steps of: 1) impregnating a fiber preform material multi-coated with pyrolytic carbon and silicon carbide to form impregnated fiber reinforced plastic composite material; 2)carbonizing the impregnated fiber reinforced plastic composite material to form carbonized fiber composite material; 3) a primary reaction-sintering of the fiber composite material; 4) cooling the primarily reaction-sintered fiber composite material down to room temperature and then impregnating the primarily reaction-sintered fiber composite material with a solution in which a polymer precursor for producing silicon carbide (SiC) is dissolved in a hexane (n-hexane) solvent; and 5) a secondary reaction-sintering of the fiber composite material; and a high-density fiber reinforced ceramic composite material manufactured using the method.

Ribbon crystal string for increasing wafer yield

A ribbon crystal has a body with a width dimension, and string embedded within the body. The string has a generally elongated cross-sectional shape. This cross-section (of the string) has a generally longitudinal axis that diverges with the width dimension of the ribbon crystal body.

Method for fabricating ceramic material

A method for a fabricating a ceramic material includes providing a mixture of a reactive metallic filler material with a preceramic polysilazane material. The preceramic polysilazane material is then polymerized to form a green body. The green body is then thermally treated in an environment that is substantially free of oxygen to convert the polymerized preceramic polysilazane material into a ceramic material that includes at least one nitride phase that is a reaction product of the reactive metallic filler material and a preceramic polysilazane material.

Method for the production of a part made from a composite material

A method of fabricating a composite part, includes forming a fiber preform for the part that is to be obtained by depositing a plurality of fiber structures impregnated with a thermoplastic polymer onto a surface, with deposition being performed by automated fiber placement; eliminating the thermoplastic polymer present in the preform by dissolution with a solvent; and injecting a liquid impregnation composition into the pores of the fiber preform after eliminating the thermoplastic polymer in order to form a matrix in the pores of the fiber preform.

METHOD FOR FABRICATING CERAMIC MATRIX COMPOSITE COMPONENTS

A method for fabricating a component according to an example of the present disclosure includes the steps of depositing a stoichiometric precursor layer onto a preform, and densifying the preform by depositing a matrix material onto the stoichiometric precursor layer. An alternate method and a component are also disclosed. 1. A method of fabricating a component , comprising the steps of:depositing a stoichiometric precursor layer onto a preform; anddensifying the preform by depositing a matrix material onto the stoichiometric precursor layer.2. The method of claim 1 , wherein the preform comprises silicon carbide fibers.3. The method of claim 1 , wherein the stoichiometric precursor layer is silicon carbide claim 1 , and wherein the ratio of silicon to carbon in the stoichiometric precursor layer is approximately one.4. The method of claim 3 , wherein the matrix material is silicon carbide and has a ratio of silicon atoms to carbon atoms claim 3 , and the ratio is approximately one.5. The method of claim 1 , wherein the step of depositing the stoichiometric precursor layer onto the preform is accomplished by an atomic layer deposition process.6. The method of claim 1 , wherein the step of densifying the preform is accomplished by a chemical vapor infiltration process.7. The method of claim 1 , wherein the matrix material comprises one or more constituents claim 1 , and further comprising the steps of:determining the ratio of the one or more constituents to one another; andcomparing the ratio to the stoichiometric ratio of the matrix material.8. The method of claim 1 , wherein the depositing step and the densifying step are performed in the same reactor.9. A ceramic matrix composite component formed by a process comprising the steps of:depositing a stoichiometric precursor layer onto a preform; anddensifying the preform by depositing a matrix material onto the stoichiometric precursor layer. This application is a continuation of U.S. application Ser. No. 15/687,625 ...

Preceramic resin formulations, impregnated fibers comprising the preceramic resin formulations, composite materials, and related methods

A preceramic resin formulation comprising a polycarbosilane preceramic polymer, an organically modified silicon dioxide preceramic polymer, and, optionally, at least one filler. The preceramic resin formulation is formulated to exhibit a viscosity of from about 1,000 cP at about 25° C. to about 5,000 cP at a temperature of about 25° C. The at least one filler comprises first particles having an average mean diameter of less than about 1.0 μm and second particles having an average mean diameter of from about 1.5 μm to about 5 μm. Impregnated fibers comprising the preceramic resin formulation are also disclosed, as is a composite material comprising a reaction product of the polycarbosilane preceramic polymer, organically modified silicon dioxide preceramic polymer, and the at least one filler. Methods of forming a ceramic matrix composite are also disclosed.

COMPOSITE MATERIAL AND METHOD FOR MAKING

A method for making a composite material includes disposing a quantity of liquid comprising at least 90 weight percent molten boron within pores of a porous preform, the preform comprising a preform material; and reacting at least a portion of the molten boron with a portion of the preform material to form a solid ceramic reaction product, thereby forming a ceramic matrix composite material. An article comprises a composite material; the composite material comprises a fibrous phase disposed within a matrix. The matrix comprises silicon carbide, boron carbide, and boron silicide. 1. A method for making a composite material , the method comprising:disposing a quantity of liquid comprising at least 90 weight percent molten boron within pores of a porous preform, the preform comprising a preform material; andreacting at least a portion of the molten boron with a portion of the preform material to form a solid ceramic reaction product, thereby forming a ceramic matrix composite material.2. The method of claim 1 , wherein the preform material comprises silicon carbide claim 1 , carbon claim 1 , boron carbide claim 1 , boron nitride claim 1 , or a combination including one or more of the foregoing.3. The method of claim 1 , wherein the preform material comprises silicon carbide.4. The method of claim 1 , wherein the preform material comprises a plurality of fibers.5. The method of claim 4 , wherein the fibers further comprise at least one coating disposed on a surface of the fibers.6. The method of claim 5 , wherein the at least one coating comprises boron nitride claim 5 , silicon-doped boron nitride claim 5 , elemental carbon claim 5 , or a combination including one or more of the foregoing.7. The method of claim 1 , further comprisingforming a scaffold comprising fibers, the fibers comprising silicon carbide; anddisposing an additional material comprising silicon carbide on the scaffold via chemical vapor infiltration to form the preform.8. The method of claim 1 , ...

Method of forming in-situ boron nitride for ceramic matrix composite environmental protection

A method for forming in situ a boron nitride reaction product locally on a reinforcement phase of a ceramic matrix composite material includes the steps of providing a ceramic matrix composite material having a fiber reinforcement material; and forming in situ a layer of boron nitride on the fiber reinforcement material.

CERAMIC MATRIX COMPOSITE AND METHOD OF MANUFACTURING THE SAME

A ceramic matrix composite includes a substrate which contains a fibrous body made of silicon carbide fiber, and a matrix which is formed in the substrate, and which contains silicon carbide and a silicon material made of silicon or a binary silicon alloy. 1. A ceramic matrix composite comprising:a substrate which contains a fibrous body made of silicon carbide fiber; anda matrix which is formed in the substrate, and which contains silicon carbide and a silicon material made of silicon or a binary silicon alloy.2. The ceramic matrix composite according to claim 1 , wherein the matrix contains no elemental carbon.3. The ceramic matrix composite according to claim 1 , whereinthe silicon carbide fiber is amorphous silicon carbide fiber, andthe silicon material is a binary silicon alloy.4. The ceramic matrix composite according to claim 2 , whereinthe silicon carbide fiber is amorphous silicon carbide fiber, andthe silicon material is a binary silicon alloy.5. The ceramic matrix composite according to claim 1 , wherein the binary silicon alloy is a Si—Y alloy claim 1 , a Si—Ti alloy or a Si—Hf alloy.6. The ceramic matrix composite according to claim 2 , wherein the binary silicon alloy is a Si—Y alloy claim 2 , a Si—Ti alloy or a Si—Hf alloy.7. The ceramic matrix composite according to claim 3 , wherein the binary silicon alloy is a Si—Y alloy claim 3 , a Si—Ti alloy or a Si—Hf alloy.8. The ceramic matrix composite according to claim 4 , wherein the binary silicon alloy is a Si—Y alloy claim 4 , a Si—Ti alloy or a Si—Hf alloy.9. A method of manufacturing a ceramic matrix composite claim 4 , comprising:a powder infiltration step of infiltrating silicon carbide powder containing no elemental carbon into a substrate which contains a fibrous body made of silicon carbide fiber; anda melt infiltration step of infiltrating a silicon material made of silicon or a binary silicon alloy into the substrate, into which the silicon carbide powder has been infiltrated, by melting the ...

Uniformity of fiber spacing in cmc materials

A pliable tape is generally provided that includes: a plurality of fibers forming unidirectional arrays of tows encased within a matrix material, with four adjacent fibers in the tape define an interstitial spacing therebetween. The matrix material comprises filler particles dispersed between adjacent fibers in the tape. In one embodiment, the filler particles have a median particle size defining the interstitial spacing such that the interstitial spacing is about 0.75 to about 1.1 of the median particle size. In another embodiment, the filler particles have a median particle size that is related to the surface-to-surface spacing between adjacent fibers, with the ratio of the surface-to-surface spacing between adjacent fibers and the median particle size being about 0.3:1 to about 1:1. Methods are also provided for forming a ceramic matrix composite.

Method for manufacturing a turbomachine blade made of composite material

A method of fabricating a turbine engine blade out of composite material including fiber reinforcement densified by a matrix, the method including using multilayer weaving to make a first fiber that has a first portion forming a blade root preform and extended by a second portion, the second portion forming a tenon preform; using multilayer weaving to make a second fiber preform, the second preform including a first portion made up of two skins defining between them an internal housing, the first portion forming an airfoil preform, and a second portion extending from an outside surface of the skins, the second portion forming a platform preform; assembling the first preform with the second preform in the non-consolidated state by engaging the second portion of the first preform in the internal housing; and co-densifying the first and second preforms as assembled together in this way to obtain a turbine engine blade.

Fiber unwinding system and methods of unwinding a fiber from a bobbin

Unwinding systems and methods are provided for unwinding a fiber from a bobbin. The unwinding system can include an axle defining a first axis extending an axial direction, a bobbin rotatably mounted around the axle, a pulley positioned to receive the fiber from the bobbin, wherein the pulley is rotatable around a second axis, and a sensor positioned between the bobbin and the pulley. The bobbin is moveable along the axial direction, and wherein the fiber extends tangentially from a surface of the bobbin.

FIBER UNWINDING SYSTEM AND METHODS OF UNWINDING A FIBER FROM A BOBBIN

Methods for coating a fiber are provided. The method can include unwinding a silicon carbide-containing fibrous material from a bobbin rotatably mounted around an axle and forming a boron nitride coating onto the silicon carbide-containing fibrous material. The bobbin is moved along the axial direction such that the silicon carbide-containing fibrous material defines an unwind angle with the axial direction, with the unwind angle being maintained between about 80° to about 100°. 1. A method of coating a fiber , the method comprising:unwinding a silicon carbide-containing fibrous material from a bobbin rotatably mounted around an axle, wherein the bobbin is moved along the axial direction such that the silicon carbide-containing fibrous material defines an unwind angle with the axial direction, the unwind angle being maintained between about 80° to about 100°; andforming a boron nitride coating onto the silicon carbide-containing fibrous material.2. The method of claim 1 , further comprising:admixing a particulate material comprising infiltration-promoting particles with said fibrous material.3. The method of claim 2 , wherein the infiltration-promoting particles are selected from the group consisting of carbon claim 2 , silicon carbide claim 2 , and mixtures thereof.4. The method of claim 2 , further comprising:forming said admixture into a preform.5. The method of claim 4 , further comprising:infiltrating said preform with an infiltrant comprising substantially molten silicon.6. The method of claim 5 , further comprising:cooling said infiltrated preform to produce the silicon-silicon carbide matrix composite.7. The method of claim 6 , wherein a weight percent of silicon in said B(Si)N coating is between about 5 to about 40 weight percent and wherein said fibrous material comprises at least 5% by volume of the composite.8. The method of claim 1 , wherein said coating substantially covers an outer surface of said fibrous material.9. The method of claim 1 , wherein ...

REMOVING COLORIZATION ON SILICON CARBIDE CERAMIC MATRIX COMPOSITES

A method of depositing silicon carbide on a preform to form a ceramic matrix composite comprises placing the preform into a reaction vessel, removing air from the reaction vessel and backfilling the reaction vessel with an inert gas to an operating pressure. The reaction vessel and the preform are heated to an operating temperature. A carrier gas and precursor materials are heated to a preheat temperature outside of the reaction vessel. The carrier gas and the precursor materials are introduced to the reaction vessel in a specified ratio. Off gasses, the precursor materials that are unspent, and the carrier gas are removed from the reaction vessel to maintain the specified ratio of the precursor materials in the reaction vessel. 1. A method of depositing silicon carbide on a preform to form a ceramic matrix composite , the method comprising:placing the preform into a reaction vessel;removing air from the reaction vessel and backfilling the reaction vessel with an inert gas to an operating pressure;heating the reaction vessel and the preform to an operating temperature;heating a carrier gas and precursor materials to a preheat temperature outside of the reaction vessel;introducing the carrier gas and the precursor materials to the reaction vessel, wherein the precursor materials are introduced in a specified ratio; andremoving off gasses, the precursor materials that are unspent, and the carrier gas from the reaction vessel to maintain the specified ratio of the precursor materials in the reaction vessel.2. The method of claim 1 , wherein the method further comprises:depositing a layer of silicon carbide on the preform with a chemical ratio of 1 atom of silicon to 1 atom of carbon.3. The method of claim 1 , wherein the method further comprises:stopping the flow of the precursor materials to the reaction vessel while removing the precursor materials that are unspent from the reaction vessel.4. The method of claim 1 , wherein the preform is made of a solid material ...

METHOD OF MAKING A CERAMIC MATRIX COMPOSITE THAT EXHIBITS MOISTURE AND ENVIRONMENTAL RESISTANCE

A method of making a ceramic matrix composite that exhibits moisture and environmental resistance has been developed. The method includes depositing a diffusion barrier layer comprising boron nitride on silicon carbide fibers and depositing a moisture-tolerant layer comprising silicon-doped boron nitride on the diffusion barrier layer, where a thickness of the moisture-tolerant layer is from about 3 to about 300 times a thickness of the diffusion barrier layer. Thus, a compliant multilayer including the moisture-tolerant layer and the diffusion barrier layer is formed. A wetting layer comprising silicon carbide, boron carbide, and/or pyrolytic carbon is deposited on the compliant multilayer layer. After depositing the wetting layer, a fiber preform comprising the silicon carbide fibers is infiltrated with a slurry. After slurry infiltration, the fiber preform is infiltrated with a melt comprising silicon and then the melt is cooled, thereby forming a ceramic matrix composite. 1. A method of making a ceramic matrix composite that exhibits moisture and environmental resistance , the method comprising:depositing a diffusion barrier layer comprising boron nitride on silicon carbide fibers;depositing a moisture-tolerant layer comprising silicon-doped boron nitride on the diffusion barrier layer, a thickness of the moisture-tolerant layer being from about 3 to about 300 times a thickness of the diffusion barrier layer, thereby forming a compliant multilayer including the moisture-tolerant layer and the diffusion barrier layer;depositing a wetting layer comprising silicon carbide, boron carbide, and/or pyrolytic carbon on the compliant multilayer layer;after depositing the wetting layer, infiltrating a fiber preform comprising the silicon carbide fibers with a slurry; andafter infiltration with the slurry, infiltrating the fiber preform with a melt comprising silicon and then cooling the melt, thereby forming a ceramic matrix composite.2. The method of claim 1 , wherein ...

Ceramic component

A ceramic component includes a porous structure that has fibers and a coating on the fibers. A ceramic material is within pores of the porous structure. A glass or glass/ceramic material is within pores of the porous structure, and one of the ceramic material or the glass or glass/ceramic material is within internal residual porosity of the other of the ceramic material or the glass or glass/ceramic material.

GAS DISTRIBUTION FOR CHEMICAL VAPOR DEPOSITION/INFILTRATION

A gas distribution plate for a chemical vapor deposition/infiltration system includes a body having a first side and a second side opposite the first side. The body may be hollow and may define an internal cavity. The gas distribution plate may also include a plurality of pass-through tubes extending through the internal cavity, a cavity inlet, and a plurality of cavity outlets. A reaction gas may be configured to flow through the plurality of pass-through tubes and a gaseous mitigation agent may be configured to flow into the internal cavity via the cavity inlet and out of the internal cavity via the plurality of cavity outlets to mix with reaction gas. 1. A system of manufacturing a ceramic matrix composite component , the system comprising:a chamber comprising an inlet portion and an outlet portion, wherein the inlet portion is configured to house a porous preform;a first inlet for introducing a gaseous precursor into the inlet portion of the chamber;a gas distribution plate disposed between the inlet portion and the outlet portion of the chamber;a second inlet for introducing a gaseous mitigation agent into an internal cavity defined in the gas distribution plate, wherein the gas distribution plate facilitates mixing the gaseous mitigation agent with a reaction gas from the inlet portion of the chamber; andan exhaust conduit coupled in fluidic communication with the outlet portion of the chamber.2. The system of claim 1 , wherein the gas distribution plate comprises a plurality of pass-through tubes claim 1 , wherein the gas distribution plate facilitates mixing the gaseous mitigation agent with the reaction gas from the plurality of pass-through tubes.3. The system of claim 1 , wherein the gas distribution plate is a first gas distribution plate claim 1 , wherein the system further comprises a second gas distribution plate.4. The system of claim 3 , wherein the second gas distribution plate is disposed between the first gas distribution plate and the outlet ...

FIBER-REINFORCED SELF-HEALING BOND COAT

An environmental barrier coating, comprising an environmental barrier coating applied to a substrate containing silicon; the environmental barrier coating comprising an oxide matrix surrounding a fiber-reinforcement structure and a self-healing phase interspersed throughout the oxide matrix. 1. An environmental barrier coating , comprising:an environmental barrier layer applied to a substrate containing silicon; said environmental barrier layer comprising an oxide matrix surrounding a fiber-reinforcement structure and a self-healing phase interspersed throughout said oxide matrix.2. The environmental barrier coating of claim 1 , wherein said substrate comprises a ceramic matrix composite material.3. The environmental barrier coating of claim 1 , wherein said fiber-reinforcement structure comprises a continuous weave of fibers.4. The environmental barrier coating of claim 1 , wherein said fiber-reinforcement structure comprises a SiC material composition.5. The environmental barrier coating of claim 1 , wherein said fiber-reinforcement structure comprises at least one first fiber bundle oriented along a load bearing stress direction of said substrate.6. The environmental barrier coating of claim 5 , wherein said substrate comprises a turbine blade claim 5 , and said load bearing stress direction is oriented along a root to tip direction.7. The environmental barrier coating of claim 5 , wherein said substrate comprises at least one of a turbine vane and a turbine blade claim 5 , and said load bearing stress direction is oriented along the contour of a platform fillet.8. The environmental barrier coating of claim 5 , wherein said fiber-reinforcement structure comprises at least one second fiber bundle oriented orthogonal to said first fiber bundle orientation.9. The environmental barrier coating of claim 8 , wherein said fiber-reinforcement structure comprises at least one third fiber woven between said first fiber bundle and said second fiber bundle.10. The ...

METHOD FOR MAKING CERAMIC MATRIX COMPOSITE ARTICLES

A method of forming a composite article may include impregnating an inorganic fiber porous preform with a first slurry composition. The slurry composition includes particles, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to substantially immobilize the particles and yield a gelled article. The method also includes impregnating the gelled article with a second solution that includes a high char-yielding component, and pyrolyzing the high char-yielding component to yield carbon and form a green composite article. The green composite article is then infiltrated with a molten metal or alloy infiltrant to form the composite article. The molten infiltrant reacts with carbon, and the final composite article may include less residual metal or alloy than a composite article formed without using the second solution. 1. A method comprising:impregnating an inorganic fiber porous preform with a first slurry composition, wherein the first slurry composition comprises ceramic particles, a solvent, and a pre-gellant material;initiating gelation of the pre-gellant material in the first slurry composition to substantially immobilize the particles and yield a gelled article;impregnating the gelled article with a second solution, wherein the second solution comprises a high char-yielding component;pyrolyzing the high char-yielding component to yield carbon and form a green composite article; andinfiltrating the green composite article with a molten metal alloy to form a final composite article, wherein at least some of the molten metal or alloy reacts with the carbon to form a metal carbide.2. The method of claim 1 , wherein the high char-yielding component comprises at least one of furfuryl alcohol or a phenolic material.3. The method of claim 1 , wherein the second solution further comprises at least one of a solvent claim 1 , a polymer interrupter claim 1 , an acid catalyst claim 1 , and a secondary polymer.4. The ...

Rapid Ceramic Matrix Composite Production Method

Ceramic matrix composite materials and a process for making said composite materials are disclosed. 1. A method of rapidly densifying a ceramic matrix composite , the method comprising:enclosing a fiber preform within a tool comprising a tool inlet and a tool outlet;loading the tool into a furnace;connecting to the tool inlet to a feed line for delivery of a gas or liquid into the tool;flowing a first gas through the feed line and into the tool, the first gas being evenly distributed through the fiber preform and first gas reactants being deposited on fibers of the fiber preform as a fiber interface coating, thereby forming a coated fiber preform;flowing a second gas through the feed line and into the tool, the second gas being evenly distributed through the coated fiber preform and second gas reactants being deposited on fibers of the coated fiber preform as a CVI matrix coating, thereby forming a CVI coated fiber preform;flowing a molten material through the feed line and into the tool for melt infiltration of the CVI coated fiber preform; andcooling the furnace, the tool dropping below a solidification temperature of the molten material, thereby rapidly densifying a ceramic matrix composite.2. The method of claim 1 , wherein the fiber interface coating and the CVI matrix coating are formed without removing the tool from the furnace.3. The method of claim 1 , wherein the CVI matrix coating is formed and the melt infiltration is carried out without removing the tool from the furnace.4. The method of wherein the fiber interface coating and the CVI matrix coating are formed and the melt infiltration is carried out without removing the tool from the furnace.5. The method of claim 1 , further comprising infiltrating the CVI coated fiber preform with a slurry.6. The method of claim 5 , wherein infiltration with the slurry takes place without removing the tool from the furnace.7. The method of claim 5 , wherein infiltration with the slurry takes place during the melt ...

METHOD OF FABRICATING A CERAMIC COMPOSITE

A method of making a ceramic composite component includes providing a fibrous preform or a plurality of fibers, providing a first plurality of particles, coating the first plurality of particles with a coating to produce a first plurality of coated particles, delivering the first plurality of coated particles to the fibrous preform or to an outer surface of the plurality of fibers, and converting the first plurality of coated particles into refractory compounds. The first plurality of particles or the coating comprises a refractory metal. 1. A component for use in ultrahigh temperatures , the component comprising:a ceramic matrix; anda plurality of refractory compounds, wherein the refractory compounds comprise a refractory metal and wherein the refractory compounds constitute 12 to 80 percent by volume of the ceramic matrix.2. The component of claim 1 , wherein the plurality of refractory compounds comprises refractory carbides or refractory borides.3. The component of claim 2 , wherein the plurality of refractory compounds comprises refractory carbides or refractory borides containing unreacted carbon or boron cores claim 2 , respectively.4. The component of and further comprising a plurality of refractory oxides distributed on a surface of the component claim 2 , wherein the refractory oxides comprise a refractory metal. The component of claim 2 , wherein the ceramic matrix comprises silicon carbide.6. The component of claim 2 , wherein the component has an inner portion and an outer portion and wherein an average size of refractory compounds in the inner portion is smaller than an average size of refractory compounds in the outer portion. The component of claim 2 , wherein at least a subset of refractory compounds of the plurality of refractory compounds have a particle size less than 0.1 micrometers.8. The component of claim 1 , wherein at least a subset of refractory compounds of the plurality of refractory compounds have a particle size ranging from 10 ...

Method of densifying a ceramic matrix composite using a filled tackifier

A method of producing an enhanced ceramic matrix composite includes applying a tackifier compound to a fiber preform. The tackifier compound includes inorganic filler particles. The method further includes modifying the tackifier compound such that the inorganic filler particles remain interspersed throughout the fiber preform, and occupy pores of fiber preform.

Composite Articles Comprising Metal Carbide Fibers

A method of producing, from a continuous or discontinuous (e.g., chopped) carbon fiber, partially to fully converted metal carbide fibers. The method comprises reacting a carbon fiber material with at least one of a metal or metal oxide source material at a temperature greater than a melting temperature of the metal or metal oxide source material (e.g., where practical, at a temperature greater than the vaporization temperature of the metal or metal oxide source material). Additional methods, various forms of carbon fiber, metal carbide fibers, and articles including the metal carbide fibers are also disclosed. 1. An article comprising:metal carbide fibers dispersed in a matrix, the metal carbide fibers comprising metal carbide in fiber form, the metal carbide comprising at least one of aluminum carbide, beryllium carbide, calcium carbide, cerium carbide, chromium carbide, dysprosium carbide, erbium carbide, europium carbide, gadolinium carbide, hafnium carbide, holmium carbide, iron carbide, lanthanum carbide, lithium carbide, magnesium carbide, manganese carbide, molybdenum carbide, niobium carbide, neodymium carbide, praseodymium carbide, samarium carbide, scandium carbide, tantalum carbide, terbium carbide, thulium carbide, thorium carbide, titanium carbide, tungsten carbide, uranium carbide, vanadium carbide, ytterbium carbide, yttrium carbide, or zirconium carbide.2. The article of claim 1 , wherein the matrix comprises at least one of a ceramic material claim 1 , a refractory carbide material claim 1 , a metal material claim 1 , a polymer material claim 1 , or combinations thereof.3. The article of claim 1 , wherein the article is one of claim 1 , or a portion of an article selected from the group comprising a magnet claim 1 , laser claim 1 , maser claim 1 , recording device claim 1 , electrical motor claim 1 , chemical reducing agent claim 1 , ceramic capacitor claim 1 , battery electrode claim 1 , hydrogen storage device claim 1 , mercury vapor lamp claim 1 ...

METHOD AND DEVICE FOR DEPOSITING A COATING ON A CONTINUOUS FIBRE

A process for depositing a coating on a continuous carbon or silicon carbide fibre from a coating precursor, includes at least heating a segment of the fibre in the presence of the coating precursor in a microwave field so as to bring the surface of the segment to a temperature enabling the coating to be formed on the segment from the coating precursor. 1. A process for depositing a coating on a continuous fibre of carbon or silicon carbide from a precursor of the coating , the process comprising:heating a segment of the fibre in the presence of the coating precursor in a microwave field so as to bring the surface of the segment to a temperature allowing the coating to form on the segment from the coating precursor, whereinthe segment of the fibre is in the presence of a gaseous phase of the coating precursor, the coating being formed by chemical vapor infiltration, the gaseous phase of the coating precursor being obtained by boiling a liquid phase of the coating precursor, the boiling resulting from contact between a hot portion of the fibre contiguous to the segment present in the microwave field and the liquid phase of the coating precursor, or whereinthe segment of fibre is in the presence of a supercritical phase of the precursor of the coating and the coating is formed by supercritical phase chemical deposition.2. The process as claimed in claim 1 , wherein claim 1 , when heating the segment of fibre claim 1 , the segment is in a first position claim 1 , and the process further comprises running the fibre so as to move the segment to a second position in which the segment is out of the microwave field.3. The process as claimed in claim 2 , wherein the running of the fibre is carried out continuously or semi-continuously.4. The process as claimed in claim 2 , wherein the unwinding of the fibre comprises unwinding the fibre from a first mandrel and winding the fibre onto a second mandrel.5. The process as claimed in claim 1 , wherein the coating is an interphase ...

HIGH STRENGTH CERAMIC FIBERS AND METHODS OF FABRICATION

A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers. A method of forming an interphase in a ceramic matrix composite material having a plurality of SiC fibers, which maximizes toughness by minimizing fiber to fiber bridging, including arranging a plurality of SiC fibers into a preform; selectively removing (e.g., etching) silicon out of the surface of the fibers resulting in a porous carbon layer on the fibers; and replacing the porous carbon layer with an interphase layer (e.g., Boron Nitride), which coats the fibers to thereby minimize fiber to fiber bridging in the preform. 1. A high performance fiber (HPF) structure , comprising:a plurality of fibers arranged in the structure;a matrix disposed between the fibers; an inner layer region having a sheet-like strength;', 'an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers., 'wherein a multilayer coating is provided along the surfaces of at least some of the fibers, the multilayer coating including2. The structure of claim 1 , wherein the inner layer region comprises graphitic carbon ...

COMPOSITE MATERIAL BASED ON C/SIC FIBERS WITH ULTRA REFRACTORY, HIGH TENACITY AND ABLATION RESISTANT MATRIX

The present invention relates to a process for the production of fiber-reinforced composite materials with an ultra-refractory, high tenacity, high ablation resistant matrix with self-healing properties, prepared from highly sinterable slurries. The composite material is produced using techniques of infiltration and drying at ambient pressure or under vacuum, and consolidated by sintering with or without the application of gas or mechanical pressure. 1. A process for the preparation of an ultra-refractory composite ceramic material comprising:(i) preparing at least one preform comprising fibers selected from among carbon fibers, silicon carbide fibers and mixtures thereof;(ii) infiltrating the at least one preform with a ceramic suspension comprising: [{'sub': 2', '2', '2, '≥70 vol. % of an ultra-refractory ceramic component selected from among ZrB, HfB, TaB, ZrC, HfC, TaC and mixtures thereof;'}, {'sub': 2', '3', '4, '≤10 vol. %, of a sintering aid selected from among ZrSi, SiNand mixtures thereof; and'}, '≤20 vol. %, of a Si compound selected from SiC, at least one organic precursor of SiC and mixtures thereof; and, '(a) a mixture of ceramic phases comprising(b) a dispersing medium selected from water, at least one organic solvent and mixtures thereof, thereby obtaining a composite material;{'sup': '5', '(iii) drying the composite material at a pressure less than or equal to about 1×10Pa; and'}(iv) consolidating the dried composite material at a temperature comprised in the range of 1700°−2000° C.2. The process according to claim 1 , wherein the fibers are carbon fibers.3. The process according to claim 1 , wherein the fibers are present in the ultra-refractory composite ceramic material in an amount comprised in the range of 30-70 vol. %.4. The process according to claim 1 , wherein the mixture of ceramic phases comprises ZrB.5. The process according to claim 1 , wherein the ultra-refractory ceramic component of step (ii) is a powder having a particle size ≤5 μm. ...

SILICON TO SILICON CARBIDE CONVERSION FOR CERAMIC MATRIX COMPOSITE FABRICATION

Disclosed are techniques and methods for producing silicon carbide and ceramic matrix composites from hydrocarbons. In one aspect, a method includes preforming a shape using silicon carbide fibers placed into a chamber, evacuating the chamber causing a silicon and polymer slurry to enter the chamber, and pressurizing the chamber causing the silicon and polymer slurry to permeate the silicon carbide fibers. The method includes heating the chamber to cause pyrolysis of the polymer and a hydrocarbon passed into the chamber into carbon and hydrogen gas. The carbon from the pyrolyzed polymer and hydrocarbon provide a coating of carbon on the silicon in the silicon and polymer slurry. The method includes heating the chamber to a higher temperature causing the silicon to melt and react with the carbon to form silicon carbide. The formed silicon carbide and the silicon carbide fibers form the ceramic matrix composite. 1. A method of producing a ceramic matrix composite , comprising:placing a silicon carbide preform in a chamber;evacuating the chamber using a vacuum to introduce a slurry mix of silicon particles and a polymer in the chamber to contact the silicon carbide preform;pressurizing the chamber causing the silicon particles and polymer slurry to permeate between the silicon carbide fibers of the silicon carbide preform;heating the chamber to a first elevated temperature causing pyrolysis of the polymer into carbon and hydrogen gas to densify silicon particles between the silicon carbide fibers of the silicon carbide preform;passing a hydrocarbon into the chamber, wherein the heated chamber causes pyrolysis of the hydrocarbon into carbon and hydrogen gas and to cause the carbon from the pyrolyzed polymer and the carbon from the pyrolyzed hydrocarbon to be coated on the silicon particles between the silicon carbide fibers of the silicon carbide preform;stopping the passing the hydrocarbon when a desired molar ratio of silicon:carbon is reached; andheating the chamber ...

INFILTRATION SYSTEM FOR A CMC MATRIX

A system of infiltration for producing a ceramic matrix composite (CMC) is provided in which a slurry is applied to an outer surface of a porous preform. The porous preform includes a framework of ceramic fibers. The slurry may include a solvent and a particulate. The porous preform may be infiltrated with the slurry. The particulate in the slurry may include a plurality of coarse particles and a plurality of fine particles. The coarse particles may have a d50 factor of 10-20 microns. The fine particles may have a d50 factor of 0.5-3 microns. A ratio of coarse particles to fine particles in the slurry may be between 1.5:1 and 4:1, inclusively. 1. A method of infiltration for producing a ceramic matrix composite (CMC) , the method comprising:applying a slurry to an outer surface of a porous preform comprising a framework of ceramic fibers, the slurry comprising a solvent and a particulate; andinfiltrating the porous preform with slurry, wherein the particulate in the slurry comprises a plurality of coarse particles and a plurality of fine particles, wherein the coarse particles have a d50 factor of 10-20 microns, wherein the fine particles have a d50 factor of 0.5-3 microns, and wherein a ratio of coarse particles to fine particles in the slurry is between 1.5:1 and 4:1, inclusively.2. The method of claim 1 , wherein a pH of the slurry is between 9 and 12 claim 1 , inclusively.3. The method of claim 1 , wherein the particulate comprises at least 55% of the slurry by volume.4. The method of claim 1 , wherein the particulate comprises at least 70% of the slurry by volume.5. The method of claim 1 , wherein the particulate includes silicon carbide.6. The method of claim 5 , wherein the solvent includes water and organic solvents.7. The method of claim 1 , wherein the porous preform is in a shape of a component for a gas turbine engine.8. The method of claim 1 , further comprising positioning the porous preform in a vacuum chamber; covering at least a portion of porous ...

METHOD FOR PRODUCING A SURFACE LAYER ON A CERAMIC MATRIX COMPOSITE

A method is provided in which a resin coating is applied to a surface of a preform. The resin coating includes a carbonaceous resin and a particulate. The preform is added to a tooling. The preform, which is positioned in the tooling, is cured. The tooling is removed. The resin coating on the surface of the preform is pyrolyzed to form a resin carbon-char layer on the surface of the preform. The preform and the resin carbon-char layer are infiltrated with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide. During the infiltration, the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform. 1. A method comprising:applying a resin coating comprising a carbonaceous resin and a particulate to a surface of a preform;adding the preform to a tooling;curing the preform positioned in the tooling;removing the tooling;pyrolyzing the resin coating on the surface of the preform to yield a resin carbon-char layer on the surface of the preform; andinfiltrating the preform and the resin carbon-char layer with silicon to form a ceramic matrix composite (CMC) component including a layer of silicon carbide, wherein during the infiltration the silicon reacts with carbon in the resin carbon-char layer to form the layer of silicon carbide on the preform.2. The method of claim 1 , further comprising controlling a viscosity of the carbonaceous resin claim 1 , such that the resin does not infiltrate the preform.3. The method of claim 2 , wherein the viscosity is in a range of 600-1200 cP claim 2 , inclusively.4. The method of claim 1 , wherein the particulate comprises silicon carbide.5. The method of claim 1 , wherein the pyrolyzing and the infiltrating are carried out simultaneously.6. The method of claim 1 , wherein the layer of silicon carbide has a thickness between 50-250 microns.7. The method of claim 1 , wherein the carbonaceous resin includes furfuryl alcohol.8. The method of claim 1 ...

ELECTRIC CABLE, CONDUCTOR, HEATING ELEMENT, METHOD FOR PRODUCING CONDUCTOR AND HEATING ELEMENT, AND HEATING DEVICE USING HEATING ELEMENT

A heating element is used, a periphery of the heating element is covered with a net-shaped conductor, the conductor and a carbon fiber bundle are electrically connected with a connecting tool at one end of the heating element, a periphery of the conductor is covered with an outer skin having flexibility, thermal conductivity and an insulating property, and the other end of the heating element is provided with a power supply terminal configured to supply power. 1. A heating element comprising:a carbide obtained by carbonizing a vegetable material containing silicon, carbon fibers each of which is continuous and obtained by mixing and spinning the carbide and resin;a carbon fiber bundle formed by bundling up the carbon fibers; anda heating unit configured to store the carbon fiber bundle in a tube having flexibility.2. The heating element according to claim 1 , wherein the carbide contains silicon in a weight ratio of 18 wt % to 35 wt %.3. A heating device comprising:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'the heating element according to ;'}a conductor which has a net shape and covers a periphery of the heating element;the conductor being electrically connected to the carbon fiber bundle with a connecting tool at one end of the heating element;an outer skin which has flexibility, thermal conductivity and an insulating property and covers a periphery of the conductor; anda power supply terminal which is provided at another end of the heating element and configured to supply power.4. The heating device according to claim 3 , wherein an air layer is provided in addition to the conductor between the tube and the outer skin.5. A method for producing a heating element comprising:a pretreatment process of drying and pulverizing a vegetable material to obtain a carbon source;a carbonization process of carbonizing the carbon source to obtain a carbide, the carbonization process including a heating process of supplying an inert gas into a chamber and heating the ...

FAST-DENSIFIED CERAMIC MATRIX COMPOSITE

A densified ceramic matrix composite (CMC) material densified CMC exhibits superior strength and toughness, relative to prior CMCs The material can be made by a process that includes impregnating a set of ceramic fibers with a non-fibrous ceramic material, resulting in a precursor matrix, stabilizing the precursor matrix, resulting in a stabilized matrix, and densifying the stabilized matrix using a frequency assisted sintering technology (FAST) process, resulting in the densified CMC material. 1. A FAST densified ceramic matrix composite material characterized by a porosity of less than 5%.2. The FAST densified ceramic matrix composite material of claim 1 , comprising a SiC fiber in a ceramic SiC matrix.3. The FAST densified ceramic matrix composite material of claim 1 , comprising a carbon fiber in a ceramic SiC matrix.4. The FAST densified ceramic matrix composite material of claim 1 , characterized by a porosity of less than 1%.5. The FAST densified ceramic matrix composite material of claim 1 , characterized by a porosity of less than 3%.6. The FAST densified ceramic matrix composite material of claim 1 , comprising an interface coating selected from pyrolytic carbon (PyC) or boron nitride (BN).7. The FAST densified ceramic matrix composite material of claim 1 , characterized by a bulk density greater than 3 g/cm. The present application is a divisional of application Ser. No. 15/372,212 filed Dec. 7, 2016, which claims priority under 35 U.S.C. §119(e) to provisional application Ser. No. 62/264,814 filed Dec. 8, 2015, which applications are incorporated herein by reference in their entireties.This invention was made with government support under contract N00014-13-P-1132 awarded by the Office of Naval Research (ONR). The government has certain rights in the invention.The present disclosure relates to methods and apparatus for fabricating ceramic matrix composites, and to the materials produced thereby.Ceramic matrix composites (CMCs) combine a ceramic fiber (e. ...

Rapid ceramic matrix composite fabrication of aircraft brakes via field assisted sintering

A method of making a ceramic matrix composite (CMC) brake component may include the steps of applying a pressure to a mixture comprising ceramic powder and chopped fibers, pulsing an electrical discharge across the mixture to generate a pulsed plasma between particles of the ceramic powder, increasing a temperature applied to the mixture using direct heating to generate the CMC brake component, and reducing the temperature and the pressure applied to the CMC brake component. The ceramic powder may have a micrometer powder size or a nanometer powder size, and the chopped fibers may have an interphase coating.

SIZED YARN INTENDED TO UNDERGO A TEXTILE OPERATION

A sized yarn for subjecting to a textile operation, the yarn including a plurality of ceramic and/or carbon fibers; an interphase coating covering the fibers; and a film covering the interphase coating and including a linear polysiloxane. 1. A sized yarn for subjecting to a textile operation , the yarn comprising:a plurality of ceramic and/or carbon fibers;an interphase coating covering the fibers; anda film covering the interphase coating and including a linear polysiloxane.2. A yarn according to claim 1 , wherein the interphase coating includes pyrolytic carbon claim 1 , boron-doped carbon claim 1 , or BN.3. A yarn according to wherein a ratio [weight of polysiloxane]/[weight of fibers+weight of interphase coating] is greater than or equal to 0.3%.4. A yarn according to claim 1 , wherein the polysiloxane is a linear poly(dimethylsiloxane).5. A yarn according to claim 1 , wherein the fibers include SiC fibers.6. A method of preparing a yarn according to claim 1 , including a step of treating a plurality of ceramic and/or carbon fibers covered in an interphase coating with a sizing composition claim 1 , the sizing composition including a linear polysiloxane.7. A method according to claim 6 , wherein claim 6 , prior to the treatment with the sizing composition claim 6 , the fibers present an initial sizing coating claim 6 , the initial sizing coating being eliminated in full or in part prior to the treatment with the sizing composition.8. A method of fabricating a fiber structure wherein one or more textile operations are performed using at least one yarn according to .9. A method according to claim 1 , wherein a woven structure is fabricated by weaving a plurality of yarns according to .10. A method according to claim 9 , wherein the yarns are wrapped before weaving claim 9 , at least one wrapping yarn being wound around each of the yarns during wrapping.11. A method according to claim 8 , wherein claim 8 , after performing the one or more textile operations claim 8 ...

COMPOSITE PART WITH SMOOTH OUTER FACE AND MANUFACTURING METHOD THEREOF

A part for an aircraft turbojet engine nacelle is made of a composite material and includes at least one outer face (S), a fibrous preform including fiber locks and having a surface(s) delimiting depressions between fiber locks, a covering material which at least partially covers the surface(s) of the fibrous preform and in particular the depressions, and a matrix which binds entirely the covering material and the fibrous preform. The covering material is a fibrous mat and the outer face (S) is smooth. A method for manufacturing such a part includes manufacturing the fibrous preform, providing a fibrous mat, depositing the fibrous preform and fibrous mat in a mold, dispersing the matrix between the fibers of the preform and mat and consolidating the fibrous preform and mat. 1. A part for an aircraft turbojet engine nacelle , the part being made of a composite material and including at least one outer face , the part comprising:a fibrous preform including fiber locks and a surface defining depressions between the fiber locks;a covering material which at least partially covers the surface of the fibrous preform and the depressions; anda matrix which binds the covering material and the fibrous preform,wherein the covering material is a fibrous mat including at least one fiber extending substantially parallel to the at least one outer face of the part and above at least one of the depressions between the fiber locks of the fibrous preform, wherein the at least one outer face is smooth.2. The part according to claim 1 , wherein a thickness of the fibrous mat is smaller than half a thickness of the fiber locks of the fibrous preform.3. The part according to claim 1 , wherein a thickness of the fibrous mat is smaller than one fifth of a thickness of the fiber locks of the fibrous preform.4. The part according to claim 1 , wherein the fibrous preform includes ceramic fibers.5. The part according to claim 1 , wherein the fibrous preform includes ceramic fibers selected from ...

SILICON CARBIDE CERAMIC

An object of the present invention is to provide an SiC ceramics having an excellent environmentally resistant coating. 1. A silicon carbide ceramics comprising a metal oxide ,the silicon carbide ceramics comprising a surface modification layer containing a silicate,the surface modification layer being derived from a raw material forming the silicon carbide ceramics, which is a matrix.2. The silicon carbide ceramics according to claim 1 , wherein the surface modification layer comprises 50 wt % or more of the silicate.3. The silicon carbide ceramics according to claim 2 , wherein the surface modification layer consists of a silicate.4. The silicon carbide ceramics according to claim 1 , wherein the surface modification layer containing a silicate is produced around the surface of the silicon carbide ceramics as a matrix.5. The silicon carbide ceramics according to claim 1 , wherein the metal oxide is at least one metal oxide selected from the group consisting of scandium oxide (ScO) claim 1 , yttrium oxide (YO) claim 1 , erbium oxide (ErO) claim 1 , ytterbium oxide (YbO) claim 1 , alumina (AlO) claim 1 , and lutetium oxide (LuO).6. The silicon carbide ceramics according to claim 1 , wherein the silicate is at least one silicate selected from the group consisting of scandium silicate (ScSiO) claim 1 , yttrium silicate (YSiO) claim 1 , erbium silicate (ErSiO) claim 1 , ytterbium silicate (YbSiO) claim 1 , ytterbium silicate (YbSiO) claim 1 , aluminum silicate (AlSiO) claim 1 , and lutetium silicate (LuSiO).7. The silicon carbide ceramics according to claim 1 , wherein the metal oxide is at least one metal oxide selected from the group consisting of scandium oxide (ScO) claim 1 , yttrium oxide (YO) claim 1 , erbium oxide (ErO) claim 1 , ytterbium oxide (YbO) claim 1 , and lutetium oxide (LuO); and{'sub': 2', '2', '7', '2', '5', '5', '2', '5', '2', '2', '7', '5, 'the silicate is at least one silicate selected from the group consisting of scandium silicate (ScSiO), ...

PRODUCTION METHOD FOR COMPOSITE MATERIAL

A production method for a composite material, which includes a porous substrate and a silicon carbide film formed on a surface of a material forming the porous substrate, includes causing a silicon source containing a silicon atom, a chlorine source containing a chlorine atom, and a carbon source containing a carbon atom to react with each other to form the silicon carbide film on the surface of the material forming the porous substrate. 1. A production method for a composite material including a porous substrate and a silicon carbide film formed on a surface of a material forming the porous substrate , the method comprising:causing a silicon source containing a silicon atom, a chlorine source containing a chlorine atom, and a carbon source containing a carbon atom to react with each other to form the silicon carbide film on the surface of the material.2. The production method for a composite material according to claim 1 , wherein a product generated by bringing the silicon source into contact with the chlorine source reacts with a gas of the carbon source.3. The production method for a composite material according to claim 2 , wherein the product is a gas containing SiClor SiCl.4. The production method for a composite material according to claim 1 , wherein the silicon source is a solid silicon and the chlorine source is a Clgas.5. The production method for a composite material according to claim 1 , wherein the silicon carbide film is formed by the reaction using a chemical vapor deposition method or a chemical vapor infiltration method.6. The production method for a composite material according to claim 1 , wherein a reaction pressure for forming the silicon carbide film is 0.1 to 20 Torr (13 to 2660 Pa).7. The production method for a composite material according to claim 1 , wherein the carbon source is at least one hydrocarbon of CH claim 1 , CH claim 1 , CH claim 1 , CH claim 1 , CH claim 1 , CH claim 1 , and CCl.8. The production method for a composite ...

Method of Forming CMC Component Cooling Cavities

A method of forming a composite component. The method includes laying up a plurality of composite plies to form a composite ply core. Another step of the method includes partially processing the composite ply core to form a green state core. The method further includes machining a cooling cavity on an exterior surface of the green state core. Additionally, the method includes inserting a filler material within the cooling cavity. A further step includes wrapping composite plies around the green state core and filler material to secure the filler material and form an outer enclosure. In one step, the method includes processing the green state core and outer enclosure to form the composite component. 1. A method of forming a composite component , comprising:laying up a plurality of composite plies to form a composite ply core;partially processing the composite ply core to form a green state core;machining a cooling cavity on an exterior surface of the green state core;inserting a filler material within the cooling cavity;wrapping composite plies around the green state core and filler material to secure the filler material and form an outer enclosure; andprocessing the green state core and outer enclosure to form the composite component.2. The method of claim 1 , further comprising:boring a film hole to fluidly couple the cooling cavity to an outer surface of the outer enclosure.3. The method of claim 1 , further comprising:machining a second cooling cavity on the exterior surface of the green state core; andinserting a second filler material within the second cooling cavity.4. The method of claim 3 , further comprising:machining a cross-over hole on the exterior surface of the green state core between the cooling cavity and the second cooling cavity.5. The method of claim 4 , further comprising:inserting a third filler material within the cross-over hole.6. The method of claim 1 , wherein at least one of the composite plies is a prepreg ply.7. The method of claim 1 , ...

Non-woven micro-trellis fabrics and composite or hybrid-composite materials reinforced therewith

A non-woven fabric is provided which includes a three-dimensional array of fibers. The three-dimensional array of fibers includes an array of standing fibers extending perpendicular to a plane of the non-woven fabric and attached to a base substrate, where the base substrate is one or more of an expendable film substrate, a metal base substrate, or a mandrel substrate. Further, the three-dimensional array of fibers includes multiple layers of non-woven parallel fibers running parallel to the plane of the non-woven fiber in between the array of standing fibers in a defined pattern of fiber layer orientations. In implementation, the array of standing fibers are grown to extend from the base substrate using laser-assisted chemical vapor deposition (LCVD).

Method of fabricating a ceramic matrix composite

A method of fabricating a ceramic matrix composite includes generating a stream of vaporized precursor and, optionally, a vaporized rare earth element. The vaporized precursor is a precursor of either silicon carbide or silicon nitride. The stream flows for one or more periods of time through a chamber that contains a fibrous structure such that the fibrous structure is exposed to the stream. The fibrous structure initially contains no silicon carbide matrix or silicon nitride matrix. The vaporized precursor deposits over the period of time on the fibrous structure as a substantially fully dense ceramic matrix of either the silicon carbide or the silicon nitride. For at least a portion of the period of time, the vaporized rare earth element is included in the stream such that the ceramic matrix deposited during that time includes dispersed rare earth element.

CONTACT INTERFACE FOR A COMPOSITE COMPONENT AND METHODS OF FABRICATION

Composite components having structurally reinforced contact interfaces are provided. In one example, the component can include an inner laminate formed of one or more inner plies having reinforcement fibers oriented along a reference direction within a matrix material. The component can also include an interface laminated positioned on the inner laminate along at least a portion of a contact surface of the component. The interface laminate is formed of one or more interface plies having reinforcement fibers oriented along a direction offset from the reference direction within a matrix material. Methods for fabricating such components are also provided. 1. A component , comprising:an inner laminate formed of one or more inner plies having reinforcement fibers embedded within a ceramic matrix material and oriented along a reference direction; anda contact interface comprising an interface laminate formed of one or more interface plies having reinforcement fibers embedded within a ceramic matrix material and oriented along a direction offset from the reference direction, wherein the outer laminate is positioned on the inner laminate.2. The component of claim 1 , wherein the reinforcement fibers of the one or more interface plies comprise silicon carbide fibers claim 1 , and wherein the ceramic matrix material of the one or more interface plies comprises silicon carbide.3. The component of claim 1 , wherein the reinforcement fibers of the one or more inner plies comprise silicon carbide fibers claim 1 , and wherein the ceramic matrix material of the one or more inner plies comprises silicon carbide.4. The component of claim 1 , wherein the one or more interface plies of the outer laminate comprise one or more first plies and one or more second plies interspersed with the one or more first plies claim 1 , and wherein the direction comprises a first direction and a second direction claim 1 , and wherein the reinforcement fibers of the one or more first plies are oriented ...

GAS DISTRIBUTION FOR CHEMICAL VAPOR DEPOSITION/INFILTRATION

A gas distribution plate for a chemical vapor deposition/infiltration system includes a body having a first side and a second side opposite the first side. The body may be hollow and may define an internal cavity. The gas distribution plate may also include a plurality of pass-through tubes extending through the internal cavity, a cavity inlet, and a plurality of cavity outlets. A reaction gas may be configured to flow through the plurality of pass-through tubes and a gaseous mitigation agent may be configured to flow into the internal cavity via the cavity inlet and out of the internal cavity via the plurality of cavity outlets to mix with reaction gas. 1. A gas distribution plate for a chemical vapor deposition/infiltration system , the gas distribution plate comprising:a body comprising a first side and a second side opposite the first side, wherein the body is hollow and defines an internal cavity;a plurality of pass-through tubes extending through the internal cavity, wherein each pass-through tube of the plurality of pass-through tubes extends from a first opening defined in the first side of the body to a second opening defined in the second side, wherein a reaction gas is configured to flow through the plurality of pass-through tubes; anda cavity inlet defined in the body, wherein a gaseous mitigation agent is configured to flow into the internal cavity of the body via the cavity inlet; anda plurality of cavity outlets defined in the second side of the body, wherein the gaseous mitigation agent is configured flow out the internal cavity via the plurality of cavity outlets.2. The gas distribution plate of claim 1 , wherein the reaction gas in the plurality of pass-through tubes is isolated from the gaseous mitigation agent in the internal cavity.3. The gas distribution plate of claim 1 , wherein the plurality of cavity outlets are distributed among the second opening of the plurality of pass-through tubes.4. The gas distribution plate of claim 1 , further ...

Systems and methods for synthesis of spheroidized metal powders

Disclosed herein are embodiments of systems and method for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertain to metal powders. Microwave plasma processing can be used to spheroidize the metal powders and form metal nitride or metal carbide powders. The stoichiometry of the metal nitride or metal carbide powders can be controlled by changing the composition of the plasma gas and the residence time of the feedstock materials during plasma processing.

Constant cross section mandrel for cmc components

A mandrel for a molding process that includes a first portion that has a first portion outer surface, a first portion inner surface, a first portion first end, and a first portion second end. A thickness of the first portion first end is greater than the first portion second end. A second portion has a second portion outer surface, a second portion inner surface, a second portion first end, and a second portion second end. A thickness of the second portion first end is smaller than the second portion second end. The first portion inner surface engages the second portion inner surface to form a mandrel that has a constant cross-section.

METHOD FOR MAKING CERAMIC MATRIX COMPOSITE ARTICLES

A method of forming a composite article may include impregnating an inorganic fiber porous preform with a first slurry composition. The slurry composition includes particles, a solvent, and a pre-gellant material. Gelling of the pre-gellant material in the slurry composition is initiated to substantially immobilize the particles and yield a gelled article. The method also includes impregnating the gelled article with a second solution that includes a high char-yielding component, and pyrolyzing the high char-yielding component to yield carbon and form a green composite article. The green composite article is then infiltrated with a molten metal or alloy infiltrant to form the composite article. The molten infiltrant reacts with carbon, and the final composite article may include less residual metal or alloy than a composite article formed without using the second solution. 1. A method comprising:impregnating an inorganic fiber porous preform with a first slurry composition, wherein the first slurry composition comprises ceramic particles, a solvent, and a pre-gellant material and does not include a high char-yielding component;initiating gelation of the pre-gellant material in the first slurry composition to substantially immobilize the ceramic particles and yield a gelled article;impregnating the gelled article with a second solution, wherein the second solution comprises the high char-yielding component;pyrolyzing the high char-yielding component to yield carbon and form a green composite article; andinfiltrating the green composite article with a molten metal alloy to form a final composite article, wherein at least some of the molten metal or alloy reacts with the carbon to form a metal carbide.2. The method of claim 1 , wherein the high char-yielding component comprises at least one of furfuryl alcohol or a phenolic material.3. The method of claim 1 , wherein the second solution further comprises at least one of a second solvent claim 1 , a polymer interrupter ...

METHOD TO FABRICATE A MACHINABLE CERAMIC MATRIX COMPOSITE

A method to form a machinable ceramic matrix composite comprises forming a porous ceramic multilayer on a surface of a fiber preform. In one example, the porous ceramic multilayer comprises a gradient in porosity in a direction normal to the surface. In another example, the porous ceramic multilayer includes low-wettability particles having a high contact angle with molten silicon, where an amount of the low-wettability particles in the porous ceramic multilayer varies in a direction normal to the surface. After forming the porous ceramic multilayer, the fiber preform is infiltrated with a melt, and the melt is cooled to form a ceramic matrix composite with a surface coating thereon. An outer portion of the surface coating is more readily machinable than an inner portion of the surface coating. The outer portion of the surface coating is machined to form a ceramic matrix composite having a machined surface with a predetermined surface finish and/or dimensional tolerance. 1. A method to form a ceramic matrix composite having a predetermined surface finish and/or dimensional tolerance , the method comprising:forming a porous ceramic multilayer on a surface of a fiber preform, the porous ceramic multilayer comprising a gradient in porosity in a direction normal to the surface;after forming the porous ceramic multilayer, infiltrating the fiber preform with a melt;cooling the melt to form a ceramic matrix composite with a surface coating thereon, an outer portion of the surface coating being more readily machinable than an inner portion of the surface coating; andmachining the outer portion to form a ceramic matrix composite having a machined surface with a predetermined surface finish and/or dimensional tolerance.2. The method of claim 1 , wherein the porosity of the porous ceramic multilayer increases in a direction away from the surface.3. The method of claim 1 , wherein the ceramic matrix composite comprises silicon carbide fibers in a matrix comprising silicon ...

Ceramic matrix composites and methods for producing ceramic matrix composites

A ceramic matrix composite includes a plurality of fibers embedded in a matrix. The composition of the matrix is selected to achieve a desired relationship between the mechanical and thermal properties of the matrix and the fibers.

Formulations with active functional additives for 3d printing of preceramic polymers, and methods of 3d-printing the formulations

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

A METHOD OF FABRICATING A CMC PART

A method of fabricating a CMC part, includes coating a plurality of tows with an interphase by transporting the tows through a treatment chamber in which a gas phase is injected, the tows being tensioned during their transport and the interphase being formed by vapor deposition from the injected gas phase; forming a fiber preform by performing three-dimensional weaving using the tows coated with the interphase; and forming a consolidated fiber preform by treating the fiber preform by chemical vapor infiltration to form a consolidation phase on the interphase, the consolidation phase comprising silicon carbide and having a Young's modulus greater than or equal to 350 GPa. 1. A method of fabricating a CMC part , the method comprising:coating a plurality of tows with an interphase by transporting the tows through a treatment chamber in which a gas phase is injected, the tows being tensioned during their transport and the interphase being formed by vapor deposition from the injected gas phase;forming a fiber preform by performing three-dimensional weaving using the tows coated with the interphase; andforming a consolidated fiber preform by treating the fiber preform by chemical vapor infiltration to form a consolidation phase on the interphase, the consolidation phase comprising silicon carbide and having a Young's modulus greater than or equal to 350 GPa, a volume fraction of the consolidation phase lying in the range from 5% to 30%.2. The method according to claim 1 , wherein the consolidation phase has a Young's modulus greater than or equal to 375 GPa.3. The method according to claim 1 , wherein the residual volume porosity of the consolidated fiber preform lies in the range 25% to 45%.4. The method according to claim 1 , the method further comprising densifying the consolidated fiber preform by forming a silicon carbide matrix phase on the consolidation phase by infiltration with a molten composition comprising silicon claim 1 , and wherein carbon and/or ceramic ...

Microstructured fiber interface coatings for composites

Disclosed is a coated ceramic fiber including a silicon carbide coating layer adjacent to the ceramic fiber and a silicon dioxide coating layer adjacent to the silicon carbide coating layer, wherein the silicon dioxide coating layer forms micro cracks after a crystal structure transformation. The coated ceramic fiber may be included in a composite material having a ceramic matrix.

Method of processing a ceramic matrix composite (cmc) component

A method of processing a CMC component includes preparing a fiber preform having a predetermined shape, and positioning the fiber preform with tooling having holes facing one or more surfaces of the fiber preform. After the positioning, a clamping pressure is applied to the tooling to force portions of the one or more surfaces of the fiber preform into the holes, thereby forming protruded regions of the fiber preform. During the application of the clamping pressure, the fiber preform is exposed to gaseous reagents at an elevated temperature, and a matrix material is deposited on the fiber preform to form a rigidized preform including surface protrusions. After removing the tooling, the rigidized preform is infiltrated with a melt for densification, and a CMC component having surface bumps is formed. When the CMC component is assembled with a metal component, the surface bumps may reduce diffusion at high temperatures.

METHOD OF FABRICATING COOLING FEATURES ON A CERAMIC MATRIX COMPOSITE (CMC) COMPONENT

A method of fabricating cooling features on a CMC component may comprise compressing a fabric preform within tooling including holes and/or recesses facing the fabric preform. During the compression, portions of the fabric preform are pushed into the holes and/or recesses. Gases are delivered through the tooling to deposit a matrix material on exposed surfaces of the fabric preform while the fabric preform is being compressed. The matrix material builds up on the portions of the fabric preform pushed into the holes and/or recesses, and a rigidized preform with surface protrusions is formed. The tooling is removed, and the rigidized preform is densified, thereby forming a CMC component including raised surface features. 1. A method of fabricating cooling features on a CMC component , the method comprising:compressing a fabric preform within tooling including holes and/or recesses facing the fabric preform, portions of the fabric preform being pushed into the holes and/or recesses;delivering gases through the tooling to deposit a matrix material on exposed surfaces of the fabric preform during the compression, the matrix material building up on the portions of the fabric preform pushed into the holes and/or recesses, thereby forming a rigidized preform with surface protrusions;removing the tooling; anddensifying the rigidized preform, thereby forming a CMC component including raised surface features.2. The method of claim 1 , wherein the gases are delivered through channels in the tooling terminating in the holes and/or recesses.3. The method of claim 1 , wherein the fabric preform comprises silicon carbide fibers and the matrix material comprises silicon carbide claim 1 ,and wherein the CMC component includes a silicon carbide matrix reinforced with the silicon carbide fibers.4. The method of claim 1 , wherein the gases include methyltrichlorosilane (CHSiCl) and hydrogen gas (H).5. The method of claim 1 , wherein the raised surface features comprise pedestals or ribs ...

METHOD OF PROCESSING A CERAMIC MATRIX COMPOSITE (CMC) COMPONENT

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. 1. A method of processing a ceramic matrix composite (CMC) , the method comprising:extracting silicon from a surface region of a CMC component such that free silicon is present in the surface region at a reduced amount of about 5 vol. % or less,wherein the extracting comprises contacting the surface region with a wicking medium comprising an element reactive with silicon.2. The method of claim 1 , further comprising forming an assembly comprising the CMC component and a metal component claim 1 , the surface region of the CMC component being in contact with the metal component claim 1 ,wherein diffusion across a CMC-metal interface is inhibited by the reduced amount of free silicon in the surface region.3. The method of claim 1 , wherein the CMC component includes a matrix comprising silicon carbide reinforced with silicon carbide fibers.4. The method of claim 1 , wherein the extraction is carried out at an elevated temperature in a range from about 1380° C. to about 1430° C.5. The method of claim 1 , wherein the element reactive with silicon is selected from the group consisting of carbon claim 1 , molybdenum claim 1 , niobium claim 1 , and tungsten.6. The method of claim 1 , wherein the wicking medium comprises a felt or powder.7. The method of claim 6 , wherein the felt has a pore size in a range from about 10 microns to about 100 microns.8. The method of claim 6 , wherein the powder has a particle size in a range from about 10 microns to about 100 microns.9. The method of claim 1 , further ...

CONTINUOUS MULTIPLE TOW COATING REACTOR

A tow coating reactor system includes a reactor for receiving fiber tow, a wedge situated adjacent the reactor and configured to receive the tow at a tip end, such that as the tow moves across the wedge, the wedge spreads the tow into a plurality of sub-tows. 1. A tow coating reactor system comprising:a reactor for receiving fiber tow; anda wedge situated adjacent the reactor and configured to receive the tow at a tip end, such that as the tow moves across the wedge, the wedge spreads the tow into a plurality of sub-tows, wherein the wedge includes a plurality of longitudinal grooves, each of the plurality of longitudinal grooves configured to receive one of the plurality of sub-tows, and the wedge includes a plurality of fins within each of the plurality of longitudinal grooves.2. The tow-coating reactor system as recited in claim 1 , wherein the wedge includes a tapered portion including a tip in line with the fiber tow.3. The tow-coating reactor system as recited in claim 2 , wherein the wedge includes an untapered portion downstream of the tapered portion.4. The tow-coating reactor system as recited in claim 1 , wherein the wedge has a coating.5. The tow-coating reactor system as recited in claim 4 , wherein the coating is a diamond-like carbon coating.6. The tow-coating reactor system as recited in claim 1 , wherein the fiber tow has a tow center axis claim 1 , the wedge having a wedge center axis claim 1 , and the tow center axis and the wedge center axis are aligned.7. The tow-coating reactor system as recited in claim 1 , wherein the wedge includes a first half surface and a second half surface opposite the first half surface claim 1 , and the wedge is positioned such that one of the plurality of sub-tows runs across the first half surface claim 1 , and a second of the plurality of sub-tows runs across the second half surface.8. The tow-coating reactor system as recited in claim 1 , comprising a second wedge opposite the reactor from the first wedge.9. The ...

Ceramic matrix composite turbine nozzle shell and method of assembly

A ceramic matrix composite turbine nozzle includes a primary outer nozzle platform; a primary inner nozzle platform; and an airfoil-shaped body extending between the primary inner and primary outer nozzle platforms. The body includes core plies defining a cavity; composite wrap plies circumscribing the core plies and defining an airfoil shape; a secondary outer nozzle platform in contact with the primary outer nozzle platform; and a secondary inner nozzle platform in contact with the primary inner nozzle platform. Each composite wrap ply has two layers of unidirectional fibers oriented transverse to each other and has first and second longitudinal edges. The first and second longitudinal edges are cut into fingers, which are folded in a transverse direction away from a turbine nozzle longitudinal axis and are interleaved between platform plies to define the secondary inner nozzle platform and the secondary outer nozzle platform.

Monomer formulations and methods for 3d printing of preceramic polymers

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

A COMPOSITE MATERIAL PART

A part made of composite material includes fiber reinforcement including silicon carbide fibers presenting an oxygen content less than or equal to 1% in atomic percentage; and a matrix present in the pores of the fiber reinforcement and including at least one sintered silicate phase including at least one rare earth silicate, mullite, or a mixture of mullite and of at least one rare earth silicate, the matrix including at least a first phase including mullite and a second phase, different from the first phase, including at least one rare earth silicate. 1. A part made of composite material comprising:fiber reinforcement comprising silicon carbide fibers presenting an oxygen content less than or equal to 1% in atomic percentage; anda matrix present in the pores of the fiber reinforcement and comprising at least one sintered silicate phase comprising at least one rare earth silicate, mullite, or a mixture of mullite and of at least one rare earth silicate, the matrix comprising at least a first phase comprising mullite and a second phase, different from the first phase, comprising at least one rare earth silicate.2. A part according to claim 1 , wherein said rare earth silicate has the chemical formula: RESiOor RESiO claim 1 , where RE designates a rare earth element.3. A part according to claim 2 , wherein RE is selected from: Y; Yb; and Lu.4. (canceled)5. A part according to claim 1 , wherein the first phase is situated between the silicon carbide fibers and the second phase.6. A part according to claim 1 , wherein the matrix comprises:at least the silicate phase comprising at least one rare earth silicate, mullite, or a mixture of mullite and of at least one rare earth silicate; andan additional matrix phase made of ceramic material, different from the silicate phase, situated between the silicon carbide fibers and the silicate phase.7. A part according to claim 1 , said part constituting a turbine engine part.8. A part according to claim 6 , the part constituting ...

Functional composite particles

A complex proppant particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant.

ACCELERATED CVI DENSIFICATION OF CMC THROUGH INFILTRATION

A process for densification of a ceramic matrix composite comprises forming a reinforcing ceramic continuous fiber stack having a central zone bounded by an outer zone adjacent; locating first particles within the central zone; coating the first particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; locating second particles within the outer zone; coating the second particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; forming the stack into a predetermined three dimensional shape; and densifying the stack. 1. A process for densification of a ceramic matrix composite comprising:forming a reinforcing ceramic continuous fiber stack having a central zone bounded by a middle zone and an outer zone adjacent said middle zone opposite said central zone;locating small particles within said central zone;coating said small particles and said ceramic fibers with silicon carbide through chemical vapor infiltration;locating medium particles within said middle zone;coating said medium particles and said ceramic fibers with silicon carbide through chemical vapor infiltration;locating large particles within said outer zone; and coating said large particles and said ceramic fibers with silicon carbide through chemical vapor infiltration;forming said preform into a predetermined three dimensional shape; anddensifying said stack.2. The process of claim 1 , wherein said reinforcing ceramic continuous fiber stack comprises fiber tows aligned into a plies claim 1 , each fiber tow having a surface having pores.3. The process of claim 2 , wherein said step of locating small particles within said central zone further comprises coating said surface of the fiber tow proximate said central zone with a slurry containing said small particles.4. The process of claim 2 , wherein said step of locating medium particles within said middle zone further comprises coating said surface of the fiber tow proximate said middle zone ...

PART COATED WITH A SURFACE COATING AND ASSOCIATED METHODS

A part made of composite material includes fiber reinforcement densified by a ceramic matrix. The part presents an outside surface and is coated over at least a portion of its outside surface by a surface coating in solid form including an alloy of silicon and nickel presenting a content by weight of silicon lying in the range 29% to 45%, or an alloy of silicon and cobalt. 1. A part made of composite material comprising fiber reinforcement densified by a ceramic matrix , the part presenting an outside surface , wherein the part is coated over at least a portion of the outside surface by a surface coating in solid form comprising an alloy of silicon and nickel presenting a content by weight of silicon lying in the range 29% to 45% , or an alloy of silicon and cobalt.2. A part according to claim 1 , wherein the surface coating comprises a phase of NiSiand/or a phase of NiSi.3. A part according to claim 1 , wherein the surface coating comprises a phase of CoSi.4. A part according to claim 1 , wherein the alloy of silicon and nickel or of silicon and cobalt is present at a content by weight greater than or equal to 5% relative to a weight of the surface coating.5. A part according to claim 1 , wherein the surface coating further includes fillers and/or a ceramic material.6. A part according to claim 1 , wherein the alloy of silicon and cobalt presents a silicon content by weight lying in the range 34% to 90%.7. A part according to claim 1 , wherein the part constitutes an aeroengine blade comprising at least a blade root and an airfoil claim 1 , and wherein the surface coating covers at least the blade root.8. A turbine engine rotor wheel comprising:a wheel disk having a blade fastener portion, said fastener portion comprising an alloy including nickel and/or cobalt; and{'claim-ref': {'@idref': 'CLM-00007', 'claim 7'}, 'a part according to , fastened to the wheel disk, the blade root of the part being mounted in the blade fastener portion.'}9. A method of fabricating a ...

METHOD OF FABRICATING A CERAMIC COMPOSITE

A method of making a ceramic composite component includes providing a fibrous preform or a plurality of fibers, providing a first plurality of particles, coating the first plurality of particles with a coating to produce a first plurality of coated particles, delivering the first plurality of coated particles to the fibrous preform or to an outer surface of the plurality of fibers, and converting the first plurality of coated particles into refractory compounds. The first plurality of particles or the coating comprises a refractory metal. 1. A method of making a ceramic composite component , the method comprising:providing a fibrous preform or a plurality of fibers;providing a first plurality of particles;coating the first plurality of particles with a coating to produce a first plurality of coated particles, wherein the first plurality of particles or the coating comprises a refractory metal;delivering the first plurality of coated particles to the fibrous preform or to an outer surface of the plurality of fibers; andconverting the first plurality of coated particles into refractory compounds.2. The method of claim 1 , wherein the first plurality of coated particles is mixed with a preceramic polymer for delivery to the preform or fibers.3. The method of and further comprising processing the preceramic polymer and refractory compounds to produce a ceramic matrix composite containing the refractory compounds.4. The method of claim 1 , wherein converting the first plurality of coated particles into refractory compounds comprises applying radiative or thermal energy to the first plurality of coated particles.5. The method of claim 1 , wherein the first plurality of particles are selected from a group consisting of powder claim 1 , platelets claim 1 , and chopped fibers.6. The method of claim 5 , wherein the coating comprises the refractory metal and the first plurality of particles comprise a material selected from the group consisting of carbon and boron.7. The ...

SIC COMPOSITE AND METHOD FOR MANUFACTURING THE SAME

The present invention relates to a SiC composite and a method for manufacturing the same. More particularly, the present invention relates to a slurry composition for ceramic matrix composites which can not only reduce the number of precursor impregnation pyrolysis (PIP) cycles but also be useful in the PIP process to increase hardness, thermal stability, and relative density. 1. A slurry composition for ceramic matrix composites , comprising:at least 58 vol % of a SiC filler;a dispersion medium; anda dispersant{'sub': 50', '50, 'wherein the SiC filler consists of only fine particles having a Ddiameter of 200 nm or less or consists of the fine particles and coarse particles having a Ddiameter of 3 μm or more in a ratio of 2:1 to 4.5:1.'}2. The slurry composition of claim 1 , wherein the SiC filler is oxidized.3. The slurry composition of claim 1 , wherein the fine particles have a Ddiameter of 100 to 200 nm and the coarse particles have a Ddiameter of 3 to 20 μm.4. The slurry composition of claim 1 , wherein the dispersion medium is water and the dispersant is included in an amount of 0.6 to 1.2 wt %.5. A SiC/SiC composite material as a matrix of a ceramic matrix composite claim 1 , the SiC/SiC composite material comprising a SiC filler and a SiC-based precursor-derived ceramic claim 1 , wherein a volume ratio of the SiC filler is 60 vol % or more based on the total volume claim 1 , and wherein the relative density of a green body manufactured by a slurry molding is 60% or more.6. A SiC particle-reinforced SiC composite densified through precursor impregnation pyrolysis (PIP) of a green body prepared by drying a slurry composition for ceramic matrix composites according to claim 1 , wherein the composite has a hardness of 10 GPa or more after 4 or less PIP cycles.7. The SiC particle-reinforced SiC composite of claim 6 , wherein an amount of a precursor-derived ceramic phase in the SiC particle-reinforced SiC composite is 9.5 to 37 vol %.8. The SiC particle- ...

Low-thickness thermostructural composite material part, and manufacture method

A thermostructural composite material part including carbon or ceramic fiber reinforcement densified by a matrix having at least one thin portion in which: the thickness of the part is less than 2 mm, or indeed less than 1 mm; the fiber reinforcement is made as a single thickness of multilayer fabric made of spread yarns having a weight of not less than 200 tex; the fiber volume ratio lies in the range 25% to 45%; and the ratio between the number of layers of the multilayer fabric and the thickness in millimeters of the part is not less than four.

Reactive melt infiltrated-ceramic matrix composite

A method includes providing a ceramic fiber preform with a range of 20 to 40 volume percent fiber which can include silicon carbide fibers; coating the ceramic fiber preform with a boron nitride interface coating; infiltrating the ceramic fiber preform with a ceramic matrix with a range of 20 to 40 volume percent silicon carbide; infiltrating the ceramic fiber preform with a constituent material such as boron carbide, boron, and carbon; and infiltrating the ceramic fiber preform with a eutectic melt material where the metallic eutectic melt can include at least one material from a group consisting of: a transition metal-silicon eutectic melt such as zirconium silicide, a transition metal-boride eutectic melt such as zirconium boride, and a transition metal-carbide eutectic melt such as zirconium carbide.

Modified atmosphere melt infiltration

A ceramic matrix composite component for use in a gas turbine engine and method for making the same are described herein. The component includes a body and an outer region. The body includes a silicon containing ceramic composite. The outer region is on an outer surface of the body.

PROTECTIVE LAYER FOR A CERAMIC MATRIX COMPOSITE ARTICLE

A method including infiltrating a porous fiber preform with a slurry including a carrier fluid and a first plurality of solid particles wherein the first plurality of solid particles includes at least a first ceramic material, drying the slurry to form a greenbody preform, machining the greenbody preform to a target dimension, depositing a protective layer precursor including a second plurality of solid particles on the machined greenbody preform wherein the second plurality of solid particles includes at least a second ceramic material, and infiltrating the machined greenbody preform with a molten infiltrant to form a composite article including an integral protective layer. 1. A method comprising:infiltrating a porous fiber preform with a slurry comprising a carrier fluid and a first plurality of solid particles, wherein the first plurality of solid particles comprises at least a first ceramic material;drying the slurry to form a greenbody preform;after drying the slurry, machining the greenbody preform to a target dimension;after machining the greenbody preform, depositing a protective layer precursor comprising a second plurality of solid particles on the machined greenbody preform, wherein the second plurality of solid particles comprises at least a second ceramic material; andinfiltrating the machined greenbody preform with a molten infiltrant to form a composite article including an integral protective layer.2. The method of claim 1 , wherein the second plurality of solid particles comprises a plurality of fine ceramic particles defining a fine particle average size claim 1 , a plurality of coarse ceramic particles defining a coarse particle average size claim 1 , and a plurality of carbon particles claim 1 , wherein the fine particle average size is less than the coarse particle average size.3. The method of claim 1 , wherein the first plurality of solid particles is different than the second plurality of solid particles.4. The method of claim 1 , wherein ...

Method of making a fiber preform for ceramic matrix composite (cmc) fabrication utilizing a fugitive binder

A method of making a fiber preform for ceramic matrix composite (CMC) fabrication comprises laminating an arrangement of fibers between polymer sheets comprising an organic polymer, which may function as a fugitive binder during fabrication, to form a flexible prepreg sheet. A plurality of the flexible prepreg sheets are laid up in a predetermined geometry to form a stack, and the stack is heated to soften the organic polymer and bond together the flexible prepreg sheets into a bonded prepreg structure. Upon cooling of the bonded prepreg structure, a rigid preform is formed. The rigid preform is heated at a sufficient temperature to pyrolyze the organic polymer. Thus, a porous preform that may undergo further processing into a CMC is formed.

A METHOD OF FABRICATING A PART OUT OF CERAMIC MATRIX COMPOSITE MATERIAL

A method of fabricating a composite material part including fiber reinforcement and a ceramic matrix present in the pores of the fiber reinforcement, the method including a) forming the fiber reinforcement by three-dimensionally weaving ceramic yarns, the fiber reinforcement as formed in this way presenting an interlock weave; b) forming a first ceramic matrix phase in the pores of the fiber reinforcement; c) after performing step b), introducing into the pores of the fiber reinforcement a powder that includes a mixture of SiC particles and of carbon particles; and d) infiltrating the fiber reinforcement obtained after performing step c), with an infiltration composition in the molten state including at least silicon so as to form a second ceramic matrix phase in the pores of the fiber reinforcement, thereby obtaining the composite material part. 1. A method of fabricating a composite material part comprising fiber reinforcement and a ceramic matrix present in pores of the fiber reinforcement , the method comprising:a) forming the fiber reinforcement by three-dimensionally weaving ceramic yarns, the fiber reinforcement as formed in this way presenting an interlock weave;b) forming a first ceramic matrix phase in the pores of the fiber reinforcement;c) after performing step b), introducing into the pores of the fiber reinforcement a powder that comprises a mixture of SiC particles and of carbon particles; andd) after performing step c), infiltrating the fiber reinforcement with an infiltration composition in the molten state comprising at least silicon so as to form a second ceramic matrix phase in the pores of the fiber reinforcement, thereby obtaining the composite material part.2. A method according to claim 1 , wherein the first ceramic matrix phase comprises silicon carbide.3. A method according to claim 1 , wherein a mean size of the particles introduced during step c) is less than or equal to 5 μm.4. A method according to claim 1 , wherein claim 1 , after ...

CERAMIC MATRIX COMPOSITE

A ceramic matrix composite of the present disclosure includes a fiber substrate including a silicon carbide fiber bundle, and a silicon carbide film formed on a surface of each silicon carbide fiber of the silicon carbide fiber bundle, in which a ratio of an average film thickness Dto an average film thickness Di is 1.0 to 1.3, the average film thickness Di being an average film thickness of the silicon carbide film formed on a surface of the silicon carbide fiber in an outer layer of the silicon carbide fiber bundle, and the average film thickness Dbeing an average film thickness of the silicon carbide film formed on a surface of the silicon carbide fiber in an inner layer, which is positioned inside the outer layer, of the silicon carbide fiber bundle. 1. A ceramic matrix composite comprising:a fiber substrate including a silicon carbide fiber bundle; anda silicon carbide film formed on a surface of each silicon carbide fiber of the silicon carbide fiber bundle,{'sub': 2', '1', '1', '2, 'wherein a ratio of an average film thickness Dto an average film thickness Dis 1.0 to 1.3, the average film thickness Dbeing an average film thickness of the silicon carbide film formed on a surface of the silicon carbide fiber in an outer layer of the silicon carbide fiber bundle, and the average film thickness Dbeing an average film thickness of the silicon carbide film formed on a surface of the silicon carbide fiber in an inner layer, which is positioned inside the outer layer, of the silicon carbide fiber bundle.'}2. The ceramic matrix composite according to claim 1 , wherein the average film thickness Dof the silicon carbide film is equal to or more than 2.6 μm. The present disclosure relates to a ceramic matrix composite.Priority is claimed on Japanese Patent Application No. 2018-109789, filed Jun. 7, 2018, the content of which is incorporated herein by reference.Ceramic matrix composites (CMCs) are known as high-strength and high-temperature materials and as lightweight ...

A METHOD OF TREATING SILICON CARBIDE FIBERS

A method of treating at least one silicon carbide fiber, the method including a) putting at least one silicon carbide fiber presenting an oxygen content that is less than or equal to 1% in atomic percentage into contact with an oxidizing medium in order to transform the surface of the fiber chemically and form a surface layer of silica; b) eliminating the resulting silica layer by putting the fiber obtained after performing step a) into contact with an acid liquid medium comprising at least hydrofluoric acid; and c) depositing an interphase layer on the surface of the fiber obtained after performing step b). 1. A method of treating at least one silicon carbide fiber , the method comprising at least the following steps:a) putting at least one silicon carbide fiber presenting an oxygen content that is less than or equal to 1% in atomic percentage into contact with an oxidizing gas phase for a duration greater than or equal to 1 min and imposing a treatment temperature greater than or equal to 600° C. in order to transform the surface of the fiber chemically and form a surface layer of silica;b) eliminating the resulting silica layer by putting the fiber obtained after performing step a) into contact with an acid liquid medium comprising at least hydrofluoric acid; andc) depositing an interphase layer on the surface of the fiber obtained after performing step b).2. A method according to claim 1 , wherein the treatment temperature imposed during step a) lies in the range 600° C. to 1000° C.3. A method according to claim 2 , wherein the treatment temperature imposed during step a) lies in the range 900° C. to 1000° C.4. A method according to claim 1 , wherein the fiber is treated during step a) with air and/or with steam.5. A method according to claim 1 , wherein the acid liquid medium comprises a mixture of hydrofluoric acid and of nitric acid.6. A method according to claim 1 , wherein the interphase layer is a layer of boron nitride or of pyrolytic carbon.7. A method ...

Method of Melt Infiltration Utilizing a Non-Wetting Coating for Producing a Ceramic Matrix Composite

A method of melt infiltration for producing a ceramic matrix composite comprises applying a non-wetting coating onto one or more outer surfaces of a porous fiber preform. The non-wetting coating comprises a non-wetting material with which molten silicon has a contact angle of at least about 45°. After applying the non-wetting coating, an uncoated portion of the porous fiber preform is immersed into a molten material comprising silicon, and the molten material is infiltrated into the porous fiber preform through the uncoated portion. The non-wetting coating serves as a barrier to inhibit or prevent the molten material from penetrating the one or more outer surfaces. After infiltration of the molten material into the porous fiber preform, the molten material is cooled to form a ceramic matrix composite, and the non-wetting coating is removed.

METHOD TO ADDITIVELY MANUFACTURE A FIBER-REINFORCED CERAMIC MATRIX COMPOSITE

A method of additively manufacturing a ceramic matrix composite material includes providing a ceramic fiber and a powdery base material for a ceramic matrix composite and layer-by-layer building up the ceramic matrix material for the ceramic matrix composite by irradiating of a powder bed formed by the base material with an energy beam according to a predetermined geometry, wherein the base material is remelted, solidified and adhesively joined to the ceramic fiber in that parameters of the energy beam are locally chosen such that in the contact region of the ceramic fiber and the powder bed, the ceramic fiber is only partly remelted. 1. A method of additively manufacturing a ceramic matrix composite comprising:providing a ceramic fiber and a powdery base material for the ceramic matrix composite,layer-by-layer building up the ceramic matrix material for the ceramic matrix composite by irradiating of a powder bed formed by the base material with an energy beam according to a predetermined geometry, wherein the base material is remelted, solidified and adhesively joined to the ceramic fiber in that parameters of the energy beam are locally chosen such that in a contact region of the ceramic fiber and the powder bed, the ceramic fiber is only partly remelted.2. The method according to claim 1 ,wherein the fiber is pre-positioned in a build space for the additive manufacture prior to the irradiation.3. The method according to claim 1 ,wherein the fiber is placed in the powder bed during the additive manufacture by a movable apparatus.4. The method according to claim 1 ,wherein a thickness of the fiber amounts to more than half of the layer thickness of the base material for the layer-by-layer build-up.5. The method according to claim 1 ,wherein a diameter of particles of the base material is five to ten times smaller than a thickness of the fiber.6. The method according to claim 1 ,wherein a mode of the irradiation with the energy beam at a transition from a powder bed ...

ARTICLE HAVING COATING INCLUDING COMPOUND OF ALUMINUM, BORON AND NITROGEN

An article includes a substrate and a coating on the substrate. The coating includes a compound of aluminum, boron and nitrogen in a continuous chemically bonded network having Al—N bonds and B—N bonds. Also disclosed is an article wherein the substrate is a plurality of fibers and the coating is a conformed coating of a compound of aluminum, boron and nitrogen having Al—N bonds and B—N bonds. The fibers are disposed in a matrix. Also disclosed is a method of protecting an article from environmental conditions. The method includes protecting a substrate that is susceptible to environmental chemical degradation using a coating that includes a compound of aluminum, boron and nitrogen having Al—N bonds and B—N bonds. 1. An article comprising:a substrate; anda coating on the substrate, the coating including a compound of aluminum (Al), boron (B) and nitrogen (N) in a continuous chemically bonded network having Al—N bonds and B—N bonds.2. The article as recited in claim 1 , wherein the compound has a composition BAlN claim 1 , where x is 0.001 to 0.999.3. The article as recited in claim 1 , wherein the coating includes an amount of B—N claim 1 , by weight claim 1 , of no greater than 50%.4. The article as recited in claim 1 , wherein the continuous chemically bonded network has a homogenous distribution of the Al—N bonds and the B—N bonds.5. The article as recited in claim 1 , wherein the Al—N bonds and the B—N bonds are molecularly distributed such that the continuous chemically bonded network has a nanodispersion of domains of the Al—N bonds and the B—N bonds.6. The article as recited in claim 1 , wherein the substrate is a plurality of fibers.7. The article as recited in claim 1 , wherein the coating has a uniform thickness and consists of the compound of aluminum (Al) claim 1 , boron (B) and nitrogen (N).8. The article as recited in claim 1 , wherein claim 1 , by weight percentage claim 1 , the coating includes a greater amount of aluminum (Al) than boron (B).9. The ...

SELF-HEALING MATRIX FOR A CERAMIC COMPOSITE

A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region. 1. A method for forming a self-healing ceramic matrix composite (CMC) component , the method comprising:depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component; anddepositing a second self-healing particulate material in a second region of the CMC preform, wherein the first and second regions are non-overlapping and wherein the second self-healing particulate material is absent from the first region;wherein the first and second self-healing particulate materials have different chemical compositions.2. The method of claim 1 , wherein the first self-healing particulate material is selected from a group consisting of silicon boride claim 1 , boron carbide claim 1 , silicon borocarbide claim 1 , silicon boronitrocarbide claim 1 , aluminum nitride and mixtures thereof claim 1 , and wherein the second self-healing particulate material is selected from a group consisting of borides of rare earth elements claim 1 , hafnium boride claim 1 , zirconium boride claim 1 , titanium boride claim 1 , tantalum boride claim 1 , silicides of rare earth elements claim 1 , hafnium silicide claim 1 , zirconium silicide claim 1 , titanium silicide claim 1 , tantalum silicide claim 1 , molybdenum disilicide claim 1 , aluminum oxide claim 1 , alkaline metal oxides claim 1 , oxide of rare earth elements claim 1 , hafnium oxide and zirconium oxide and mixtures thereof.3. The method of claim 2 , wherein the first region comprises an inner core of the CMC preform claim 2 , and wherein the second region comprises an outer region of the CMC ...

ADDITIVE MANUFACTURING TECHNIQUE FOR PLACING NUCLEAR REACTOR FUEL WITHIN FIBERS

Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure. 1. A method of forming at least part of a fiber , comprising: providing precursors in a reactor; and', 'forming nuclear fuel material as at least part of the fiber in the reactor from the precursors, including using chemical deposition interacting with said precursors to deposit the nuclear fuel material., 'forming at least part of the fiber having nuclear fuel material therein, the forming comprising2. The method of claim 1 , wherein said chemical deposition comprises laser chemical vapor deposition.3. The method of claim 2 , wherein said forming includes:providing a plurality of fibers in the reactor; andusing a laser which interacts with the plurality of fibers and the precursors to deposit the nuclear fuel material over respective portions of the plurality of fibers.4. The method of claim 2 , wherein said forming includes:growing a plurality of fibers, including using a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber of the plurality of fibers.5. The method of claim 1 , wherein the ...

METHOD FOR PRODUCING CERAMIC MATRIX COMPOSITE

A production method for a ceramic matrix composite is comprised of: compounding an aggregate powder including a ceramic and a binder including at least one of thermoplastic resins and waxes to form a composition of the aggregate powder and the binder; pressing the composition to form sheets; accumulating fabrics of reinforcement fibers including the ceramic and the sheets alternately; pressing an accumulated body of the fabrics and the sheets; and generating a matrix combining the reinforcement fibers together. 1. A production method for a ceramic matrix composite , comprising:compounding an aggregate powder including a ceramic and a binder including at least one of thermoplastic resins and waxes to form a composition of the aggregate powder and the binder;pressing the composition to form sheets;accumulating fabrics of reinforcement fibers including the ceramic and the sheets alternately;pressing an accumulated body of the fabrics and the sheets; andgenerating a matrix combining the reinforcement fibers together.2. The production method of claim 1 , wherein the ceramic includes SiC.3. The production method of claim 1 , wherein the step of generating the matrix includes molten metal infiltration claim 1 , gas phase infiltration claim 1 , liquid phase infiltration claim 1 , and solid phase infiltration.4. The production method of claim 1 , wherein the aggregate powder includes C powder and the step of generating the matrix includes adhering an ingot of Si or a Si alloy to the accumulated body and heating the ingot up to a temperature at which the ingot melts.5. The production method of claim 1 , further comprising:at the same time of, or after, the step of pressing, carrying out near-net-shape molding with the accumulated body.6. The production method of claim 1 , further comprising:coating the reinforcement fibers with C or BN. This application is a Continuation Application of PCT International Application No. PCT/JP2016/052024 (filed Jan. 25, 2016), which is in turn ...

HIGH STRENGTH CERAMIC FIBERS AND METHODS OF FABRICATION

A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers. A method of forming an interphase in a ceramic matrix composite material having a plurality of SiC fibers, which maximizes toughness by minimizing fiber to fiber bridging, including arranging a plurality of SiC fibers into a preform; selectively removing (e.g., etching) silicon out of the surface of the fibers resulting in a porous carbon layer on the fibers; and replacing the porous carbon layer with an interphase layer (e.g., Boron Nitride), which coats the fibers to thereby minimize fiber to fiber bridging in the preform. 1. A high performance fiber (HPF) structure , comprising:a plurality of fibers arranged in the structure;a matrix disposed between the fibers; an inner layer region having a sheet-like strength;', 'an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers., 'wherein a multilayer coating is provided along the surfaces of at least some of the fibers, the multilayer coating including2. The structure of claim 1 , wherein the inner layer region comprises graphitic carbon ...

IMPREGNATED FIBERS COMPRISING PRECERAMIC RESIN FORMULATIONS, AND RELATED COMPOSITE MATERIALS AND METHODS

A preceramic resin formulation comprising a polycarbosilane preceramic polymer, an organically modified silicon dioxide preceramic polymer, and, optionally, at least one filler. The preceramic resin formulation is formulated to exhibit a viscosity of from about 1,000 cP at about 25° C. to about 5,000 cP at a temperature of about 25° C. The at least one filler comprises first particles having an average mean diameter of less than about 1.0 μm and second particles having an average mean diameter of from about 1.5 μm to about 5 μm. Impregnated fibers comprising the preceramic resin formulation are also disclosed, as is a composite material comprising a reaction product of the polycarbosilane preceramic polymer, organically modified silicon dioxide preceramic polymer, and the at least one filler. Methods of forming a ceramic matrix composite are also disclosed. 1. Impregnated fibers comprising fibers and a preceramic resin formulation comprising a polycarbosilane preceramic polymer , an organically modified silicon dioxide preceramic polymer , and at least one filler , the at least one filler comprising first particles having an average mean diameter of less than about 1.0 μm and second particles having an average mean diameter of from about 1.5 μm to about 5 μm.2. The impregnated fibers of claim 1 , wherein the fibers comprise polyacrylonitrile-based fibers.3. The impregnated fibers of claim 1 , wherein the fibers comprise pitch-based fibers.4. A composite material comprising fibers and a reaction product of a polycarbosilane preceramic polymer claim 1 , an organically modified silicon dioxide preceramic polymer claim 1 , and at least one filler claim 1 , the at least one filler comprising first particles having an average mean diameter of less than about 1.0 μm and second particles having an average mean diameter of from about 1.5 μm to about 5 μm.5. The composite material of claim 4 , wherein the composite material is configured as at least a portion of a rocket ...

TUBULAR BODY CONTAINING SiC FIBERS

Provided is a tubular body containing SiC fibers having high thermal conductivity. The tubular body containing SiC fibers includes a SiC fiber layer wound in a tubular form, an inner SiC coating layer covering an inner surface of the SiC fiber layer, and an outer SiC coating layer covering an outer surface of the SiC fiber layer. The inner and outer SiC coating layers are bound to each other in gaps provided in the SiC fiber layer. 1. A tubular body containing SiC fibers , the tubular body comprising:a SiC fiber layer wound in a tubular form;an inner SiC coating layer covering an inner surface of the SiC fiber layer; andan outer SiC coating layer covering an outer surface of the SiC fiber layer,wherein the inner SiC coating layer and the outer SiC coating layer are bound to each other in gaps provided in the SiC fiber layer.2. The tubular body containing SiC fibers according to claim 1 ,wherein the inner SiC coating layer is composed of sintered SiC.3. The tubular body containing SiC fibers according to claim 1 ,wherein the tubular body has a cross-sectional shape of a polygon, circle, ellipse, or round shape having irregularities on an outer circumference thereof. The present invention relates to a tubular body containing SiC fibers that is particularly applicable to, for example, nuclear fuel cladding tubes.Zircaloy (an alloy of zirconium) that is low in neutron absorption and has corrosion resistance and mechanical strength has been widely used for cladding tubes for storing nuclear fuel.Zircaloy, however, has properties of reacting with the surrounding water (coolant) and generating hydrogen when it reaches a specific temperature. This reaction is an exothermic reaction that involves a rapid temperature rise, and thus has been one of the causes for loss of nuclear power control resulting in serious accidents.Some cladding tubes including SiC (silicon carbide) have been recently proposed. Silicon carbide is a material that is resistant to heat, chemically stable, ...

Controlling microstructure of inorganic material by indirect heating using electromagnetic radiation

Disclosed is a method for controlling a microstructure of an inorganic material includes providing a structure that has a first region of an inorganic material having a first microstructure and a second region that is thermally responsive to electromagnetic radiation, the second region being adjacent the first region, and indirectly heating the first region by thermally activating the second region, using electromagnetic radiation, to generate heat. The generated heat converts the first microstructure of the inorganic material to a second, different microstructure. The method can be applied to control a microstructure of an inorganic coating on an inorganic fiber.

Cvi matrix densification process

Disclosed herein is a chemical vapor infiltration method including flowing ceramic precursors through a preform and depositing a matrix material on the preform at a first gas infiltration pressure, increasing the gas filtration pressure to a second gas infiltration pressure, and lowering the gas infiltration pressure to a third gas infiltration pressure which is intermediate to the first and second gas infiltration pressures.

CONFORMAL COMPOSITE COATINGS AND METHODS

An embodiment of an article includes a substrate and a conformal coating. The conformal coating includes a first particulate layer between a first matrix layer and a second matrix layer. The first particulate layer includes a first plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout the first particulate layer, and a ceramic matrix material disposed between individual ones of the first plurality of particles. 1. An article comprising:a substrate; and a first matrix layer including primarily a ceramic matrix material;', 'a second matrix layer including primarily the ceramic matrix material; and', 'a first particulate layer disposed between the first and second matrix layers, the first particulate layer including a plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout the first particulate layer, and the ceramic matrix material disposed between individual ones of the first plurality of particles., 'a conformal coating comprising2. The article of claim 1 , wherein the substrate comprises a fiber formed from one of a group consisting of: oxide ceramic fibers claim 1 , carbide ceramic fibers claim 1 , nitride ceramic fibers claim 1 , boride ceramic fibers claim 1 , phosphide ceramic fibers claim 1 , glass-ceramic fibers claim 1 , oxycarbide fibers claim 1 , oxynitride fibers claim 1 , metal fibers claim 1 , glass fibers claim 1 , and carbon fibers.3. The article of claim 2 , wherein the fiber comprises silicon carbide (SiC).4. The article of claim 1 , wherein the first plurality of inorganic particles is selected from glass claim 1 , carbides claim 1 , oxides claim 1 , nitrides claim 1 , borides claim 1 , phosphides claim 1 , sulfides claim 1 , and combinations thereof.5. The article of claim 1 , wherein the ceramic matrix material comprises silicon carbide (SiC).6. The article of claim 1 , further comprising:a second particulate layer disposed adjacent to one of the first and ...

ENVIRONMENTAL BARRIER FIBER COATING

A fiber having an environmental barrier coating is provided that includes, in one illustrative form, a Hi Nicalon preform assembled in a tooling for chemical vapor infiltration and cleaned to remove sizing char from fibers of the Hi Nicalon preform; a ytterbium doped silicon carbide coat located over the Hi Nicalon preform; a boron nitride interface coat applied over the ytterbium doped silicon carbide coat; and a silicon carbide coat applied over the boron nitride interface coat. 1. A fiber having an environmental barrier coating , the fiber comprising:a silicon carbide fiber;an environmental barrier coating comprising yttrium doped silicon carbide on the silicon carbide fiber; andan interface coating comprising silicon doped boron nitride applied over the environmental barrier coating.2. The fiber of claim 1 , further comprising a structural coating applied over the interface coating.3. The fiber of claim 2 , wherein the structural coating comprises multiple layers.4. The fiber of claim 3 , wherein the multiple layers include a silicon nitride layer and a silicon carbide layer.5. The fiber of claim 4 , wherein the silicon nitride layer is about 0.3 μm in thickness and the silicon carbide layer is about 0.1 μm in thickness.6. The fiber of claim 1 , wherein the environmental barrier coating has a thickness from about 0.01 micron to about 2 microns.7. The fiber of claim 6 , wherein the environmental barrier coating has a thickness of 1 μm.8. The fiber of claim 1 , wherein the interface coating has a thickness of about 0.3 μm.9. The fiber of claim 1 , wherein the environmental barrier coating is bonded to the silicon carbide fiber.10. The fiber of claim 1 , further comprising other functional coatings between the environmental barrier coating and the interface coating.11. The fiber of claim 1 , wherein the silicon carbide fiber comprises a Hi Nicalon S fiber.12. The fiber of claim 1 , wherein the silicon carbide fiber is coated in tow form. The present patent document ...

SELF-HEALING MATRIX FOR A CERAMIC COMPOSITE

A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region. 1. A ceramic matrix composite (CMC) component comprising:a plurality of fibers; and a first region comprising deposits of a first self-healing material capable of sealing cracks in the matrix; and', 'a second region distinct from the first region and comprising deposits of a second self-healing material capable of regenerating an environmental barrier coating;', 'wherein the deposits of the first and second self-healing materials are dispersed throughout the matrix in each of the first and second regions., 'a ceramic matrix, wherein the plurality of fibers are embedded in the ceramic matrix and wherein the ceramic matrix comprises2. The CMC component of claim 1 , wherein the first self-healing material is selected from a group consisting of silicon boride claim 1 , boron carbide claim 1 , silicon borocarbide claim 1 , silicon boronitrocarbide claim 1 , and mixtures thereof claim 1 , and wherein the second self-healing material is selected from a group consisting of borides of rare earth elements claim 1 , hafnium boride claim 1 , zirconium boride claim 1 , titanium boride claim 1 , tantalum boride claim 1 , silicides of rare earth elements claim 1 , hafnium silicide claim 1 , zirconium silicide claim 1 , titanium silicide claim 1 , tantalum silicide claim 1 , molybdenum disilicide claim 1 , aluminum oxide claim 1 , alkaline metal oxides claim 1 , oxide of rare earth elements and mixtures thereof.3. The CMC component of claim 1 , wherein the first region comprises an inner core of the CMC component and wherein the second region comprises an outer region of the ...

COATING FIBERS USING DIRECTED VAPOR DEPOSITION

A method of making a fiber tow coating is provided. The method includes providing a fiber tow selected from the group consisting of carbon and silicon; and applying an oxide-based fiber interface coating onto the fiber tow using directed vapor deposition or other like deposition method. 1. A coated fiber tow comprising:a fiber tow comprising a material selected from the group consisting of at least one of a carbon material and a silicon material;an oxide-based fiber interface coating on the fiber tow; anda Si-based coating on the oxide-based fiber interface coating, wherein the Si-based coating comprises a material selected from the group consisting of silicon carbide, silicon nitride, Si—N—C, and Si—C—O.2. The coated fiber tow of claim 1 , wherein the oxide-based fiber interface coating comprises a ceramic oxide.3. The coated fiber tow of claim 2 , wherein the ceramic oxide is selected from the group consisting of a rare earth monosilicate claim 2 , a rare earth disilicate claim 2 , barium strontium aluminosilicate claim 2 , mullite claim 2 , yttrium aluminum garnet claim 2 , and a rare earth monazite.4. The coated fiber tow of claim 3 , wherein a base of the rare earth monosilicate and a base of the rare earth disilicate is selected from the group consisting of scandium claim 3 , yttrium claim 3 , lanthanum claim 3 , cerium claim 3 , praseodymium claim 3 , neodymium claim 3 , promethium claim 3 , samarium claim 3 , europium claim 3 , gadolinium claim 3 , terbium claim 3 , dysprosium claim 3 , holmium claim 3 , erbium claim 3 , thulium claim 3 , ytterbium claim 3 , and lutetium.5. The coated fiber tow of claim 3 , wherein a base of the rare earth monazite is selected from the group consisting of lanthanum claim 3 , cerium claim 3 , praseodymium claim 3 , and neodymium.6. The coated fiber tow of claim 1 , wherein the oxide-based fiber interface coating comprises yttrium disilicate claim 1 , ytterbium disilicate claim 1 , barium strontium aluminosilicate claim 1 , or ...

CERAMIC HONEYCOMB BODY FOR LIGHTWEIGHT STRUCTURES AND CORRESPONDING PRODUCTION METHOD

A honeycomb body made of a composite material for fire-resistant lightweight structures including honeycomb cells having a cross section is provided. The cell walls of the honeycomb cells are produced from a composite material. The composite material has at least one carrier, for example a woven fabric or a laid fabric made of fibers, and a matrix into which the carrier is embedded. The matrix includes a silicon-based ceramic material, of which the proportion by mass in the matrix along the cell walls is at least 30 wt. %. A method for producing such a ceramic honeycomb body and a honeycomb tube as an intermediate product for the same are also provided. A flat semi-finished product as a curable intermediate product for the production of fire-resistant fiber composite lightweight structures, which has a matrix mixture including dispersed silicon particles, is also provided. 1141441121312. A honeycomb body () of a composite material for fire-resistant lightweight structures , in particular for use as or for producing a core () between two cover layers () of a lightweight sandwich structure , the honeycomb body () comprising honeycomb cells () with a cross-section in the L/W plane , in particular a polygonal , preferably approximately hexagonal cross-section , cell walls () of the honeycomb cells () being produced from a composite material , the composite material at least comprisinga support, in particular a woven or laid fabric made of fibers, anda matrix, the support being embedded in the matrix,{'b': '13', 'characterized in that the matrix comprises a silicon-based ceramic material selected from the group consisting of silicon carbide, silicon oxycarbide, silicon nitride, silicon carbonitride and silicon-boron carbonitride, wherein, over the entire height of the cell walls () in the T direction perpendicular to the L/W plane, the matrix has a mass fraction of the silicon-based ceramic material of at least 30 wt. %, in particular of at least 40 wt. % and preferably ...

METHOD FOR MANUFACTURING A PART MADE FROM CMC

A process for manufacturing a part made of composite material with a matrix at least predominantly made of ceramic includes producing a fibrous structure by three-dimensional or multilayer weaving; shaping the fibrous structure to form a fibrous preform core; depositing an interphase on the fibers of the preform core; consolidating the preform core by partial densification of the core including the formation of a matrix phase by chemical vapor infiltration or by a liquid process; depositing a powder of ceramic particles in the porosity of the preform core; draping one or more layers of pre-impregnated non-woven fibers over all or part of the outer surface of the preform core; heat treatment of the preform core and of the pre-impregnated layer(s) to form a hybrid fibrous preform; further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon to obtain a ceramic matrix composite part. 1. A process for manufacturing a part made of a composite material with a matrix at least predominantly made of ceramic , the process comprising:producing a fibrous structure by three-dimensional or multilayer weaving;shaping the fibrous structure to form a fibrous preform core;depositing an interphase on the fibers of the preform core;consolidating the preform core by partial densification of said core comprising the formation of a matrix phase by chemical vapor infiltration or by a liquid process;depositing a powder of ceramic particles in the porosity of the preform core;draping one or more layers of pre-impregnated non-woven fibers over all or part of the outer surface of the preform core;performing a heat treatment of the preform core and of the pre-impregnated layer(s) to form a hybrid fibrous preform;further densifying by infiltration of the hybrid fibrous preform with an infiltration composition containing at least silicon in order to obtain a ceramic matrix composite part.2. The process as claimed in claim 1 , ...

Method For Combined Desizing And Interface Coating Of Fibers For Ceramic Matrix Composites

A method of preparing a fiber for use in forming a ceramic matrix composite material comprises the steps of removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber, and using the pyrolyzed remnants as a reactant to provide an interface coating on the fiber. 1. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber; andusing the pyrolyzed remnants as a reactant to provide an interface coating on the fiber.2. The method according to wherein the organic sizing comprises a polymer based coating.3. The method according to wherein the polymer based coating further comprises carbon nanotubes.4. The method according to including subsequently forming a layer that includes boron nitride nanotubes.5. The method according to wherein the polymer based coating further comprises select inorganic additives or catalysts.6. The method according to wherein the pyrolyzed remnants include residual carbon.7. The method according to including providing a heat treatment with a material comprising a solid species that includes at least boron to provide the interface coating.8. The method according to wherein the heat treatment occurs in a vacuum.9. The method according to wherein the heat treatment occurs approximately at 100 mTorr pressure or less.10. The method according to wherein the heat treatment occurs approximately at 1450° Celsius or less.11. The method according to including providing an additional heat treatment in nitrogen to provide a boron carbide claim 8 , a boron nitride coating claim 8 , and/or a boron nitride coating that includes carbon.12. The method according to wherein the heat treatment occurs in nitrogen.13. The method according to wherein the heat treatment occurs approximately at 1450° Celsius or less.14. The method according to including providing an additional heat treatment in nitrogen with silicon ...

ADDITIVE LAYER METHOD FOR APPLICATION OF SLURRY-BASED FEATURES

A system and method for forming a porous ceramic preform is provided. The method may include forming a stacked powder structure including a binder layer and a powder layer on the binder layer. The binder layer may be formed by depositing a binder with a spray nozzle on a substrate. The powder layer may be formed by depositing a powder on the binder layer. The porous ceramic preform may be formed by heating the stacked powder structure to pyrolyze the binder. The porous ceramic preform is configured to be infiltrated by a molten material. The substrate may comprise a ceramic fiber preform. After melt infiltration of the porous ceramic preform and the ceramic fiber preform, a densified ceramic feature having a predetermined geometry may be formed on a ceramic matrix composite (CMC) component. 1. A method comprising:forming a stacked powder structure comprising a binder layer and a powder layer on the binder layer, wherein forming the stacked powder structure comprises forming the binder layer by depositing a binder with a spray nozzle on a substrate and forming the powder layer on the binder layer by depositing a powder on the binder layer; andforming a porous ceramic preform by heating the stacked powder structure to pyrolyze the binder, the porous ceramic preform configured to be infiltrated by a molten material.2. The method of claim 1 , further comprising:removing an amount of the powder from the stacked powder structure prior to forming the porous ceramic preform.3. The method of claim 1 , wherein the powder comprises fibers claim 1 , and the method further comprises:infiltrating the porous ceramic preform with the molten material resulting in a densified composite feature having a fiber-to-ceramic matrix material ratio of between 20% and 45%.4. The method of claim 1 , wherein the powder comprises at least one of silicon carbide claim 1 , nitride claim 1 , or a metallic carbide.5. The method of claim 1 , wherein the spray nozzle comprises an array of nozzles for ...

METHOD OF FORMING A CERAMIC MATRIX COMPOSITE (CMC) COMPONENT HAVING AN ENGINEERED SURFACE

A method of forming a ceramic matrix composite (CMC) component having an engineered surface includes applying a surface slurry comprising first particulate solids in a liquid carrier to an outer surface of a ceramic fiber preform. The surface slurry is dried to remove the liquid carrier, and thus a surface slurry layer comprising the first particulate solids is formed on the outer surface. The surface slurry layer is polished to a predetermined thickness and/or surface finish. After polishing, a ceramic tape comprising second particulate solids is applied to the surface slurry layer, and pressure is applied to attach the ceramic tape to the surface slurry layer and to induce consolidation of the ceramic tape and the surface slurry layer. Thus, a multilayer surface region comprising the surface slurry layer and a ceramic tape layer is formed on the ceramic fiber preform. The ceramic fiber preform and the multilayer surface region are infiltrated with a molten material, and, upon cooling, a CMC component having an engineered surface is formed. 1. A method of forming a ceramic matrix composite (CMC) component having an engineered surface , the method comprising:applying a surface slurry to an outer surface of a ceramic fiber preform, the surface slurry including first particulate solids in a liquid carrier;drying the surface slurry to remove the liquid carrier, thereby forming a surface slurry layer comprising the first particulate solids on the outer surface;polishing the surface slurry layer to a predetermined thickness and/or surface finish;after polishing, applying a ceramic tape to the surface slurry layer, the ceramic tape comprising second particulate solids,applying pressure to the ceramic tape to attach the ceramic tape to the surface slurry layer and to induce consolidation of the ceramic tape and the surface slurry layer, thereby forming a multilayer surface region comprising the surface slurry layer and a ceramic tape layer on the ceramic fiber preform; ...

Internal cooling circuits for cmc and method of manufacture

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.

Doped silicon carbide ceramic matrix composite

A method for forming ceramic matrix composite (CMC) component includes forming a fiber preform, positioning the fiber preform into a chemical vapor infiltration reactor chamber, and densifying the fiber preform. Densification includes infiltrating the fiber preform with a first gas comprising precursors of silicon carbide and infiltrating the fiber preform with a second gas comprising a first rare earth element, wherein the steps of infiltrating the fiber preform with the first gas and infiltrating the fiber preform with the second gas are conducted simultaneously to produce a first rare earth-doped silicon carbide matrix in a first region of the component.

METHOD FOR PRODUCING A HOLLOW PART MADE OF A CERAMIC MATRIX COMPOSITE MATERIAL

The invention relates to a method for producing a hollow part made of a ceramic matrix composite material comprising the steps of: 1. A method for producing a hollow part made of a ceramic matrix composite material comprising the steps of:shaping a hollow fibrous preform, a core made of an oxidizable material being housed or inserted into the preform;consolidating said preform; andextracting the core by oxidising said core.2. The method according to claim 1 , wherein the step of extracting the core by oxidising said core comprises the following sub-steps:heating the preform in which the core is inserted, in a furnace under an oxidising atmosphere; andmechanically removing the oxidised core.3. The method according to claim 2 , wherein said heating is carried out in the presence of a catalyst.4. The method according to claim 2 , wherein said heating is carried out at a temperature ranging from 400° C. to 800° C.5. The method according to claim 2 , wherein said heating comprises:a first heating cycle lasting between 20 hrs and 30 hrs; anda second heating cycle lasting between 10 hrs and 15 hrs.6. The method according to claim 1 , wherein the oxidizable core is made of carbon claim 1 , graphite or other material derived from carbon.7. The method according to claim 1 , wherein the hollow fibrous preform is made by draping or assembling fibrous textures around the core claim 1 , or by weaving a preform having a hollow area for insertion of the core.8. The method according to claim 1 , wherein said consolidation of the preform comprises the sub-steps of:creating at least one interphase on the fibres of the fibrous preform by chemical vapour infiltration; andcreating at least one ceramic matrix layer on the interphase by chemical vapour infiltration.9. The method according to claim 1 , wherein the step of extracting the core by oxidation is followed by a step of densification of the preform comprising:the introduction of a metal powder into the preform; andthe infiltration ...

COMPOSITES AND METHODS OF FORMING COMPOSITES HAVING AN INCREASED VOLUME OF CERAMIC PARTICLES

A fiber reinforced composite component may include interleaved textile layers and ceramic particle layers coated with matrix material. The fiber reinforced composite component may be fabricated by forming a fibrous preform and densifying the fibrous preform. The fibrous preform may be fabricated by forming a first ceramic particle layer over a first textile layer, disposing a second textile layer over the first ceramic particle layer, forming a second ceramic particle layer over the second textile layer, and disposing a third textile layer over the second ceramic particle layer. 1. A method of fabricating a composite component , comprising: forming a first ceramic particle layer over a first textile layer;', 'disposing a second textile layer over the first ceramic particle layer;', 'forming a second ceramic particle layer over the second textile layer; and', 'disposing a third textile layer over the second ceramic particle layer; and, 'forming a fibrous preform bydensifying the fibrous preform.2. The method of claim 1 , further comprising performing a silicon melt infiltration after the densifying the fibrous preform.3. The method of claim 1 , wherein forming the first ceramic particle layer comprises depositing a first volume of boron carbide powder over the first textile layer claim 1 , and wherein forming the second ceramic particle layer comprises depositing a second volume of boron carbide powder over the second textile layer.4. The method of claim 3 , wherein forming the fibrous preform further comprises:locating a first shim around an outer perimeter of the first textile layer; andlocating a second shim around an outer perimeter of the second textile layer.5. The method claim 4 , wherein forming the fibrous preform further comprises:removing a portion of the first volume of boron carbide powder extending beyond an upper surface of the first shim; andremoving a portion of the second volume of boron carbide powder extending beyond an upper surface of the second ...

Environment-resistive coated reinforcement fiber applicable to fiber-reinforced composite

A high-temperature-steam-oxidation-resistive coated reinforcement fiber applicable to a fiber reinforced composite, is provided with: a reinforcement fiber; a coating layer covering the reinforcement fiber and including a rare-earth silicate; an exfoliative layer intervening in an interface between the coating layer and the reinforcement fiber; and a supplemental coating layer covering the reinforcement fiber, the exfoliative layer and the coating layer.

METHOD OF DENSIFYING A CERAMIC MATRIX COMPOSITE USING A FILLED TACKIFIER

A method of producing an enhanced ceramic matrix composite includes applying a tackifier compound to a fiber preform. The tackifier compound includes inorganic filler particles. The method further includes modifying the tackifier compound such that the inorganic filler particles remain interspersed throughout the fiber preform, and occupy pores of fiber preform. 1. A method of producing an enhanced ceramic matrix composite , the method comprising:applying a tackifier compound to a fiber preform, the tackifier compound comprising inorganic filler particles; andmodifying the tackifier compound such that the inorganic filler particles remain interspersed throughout the fiber preform and occupy pores of the fiber preform.2. The method of and further comprising: coating the fiber preform with an interface coating using a chemical vapor infiltration or chemical vapor deposition process.3. The method of and further comprising: forming a matrix surrounding the fiber preform using a chemical vapor infiltration or chemical vapor deposition process.4. The method of and further comprising: applying a thermal barrier coating or an environmental barrier coating to the ceramic matrix composite.5. The method of claim 1 , wherein the tackifier compound further comprises a solvent and a resin.6. The method of claim 5 , wherein the solvent comprises water claim 5 , acetone claim 5 , ethanol claim 5 , isopropanol claim 5 , or toluene.7. The method of claim 5 , wherein the resin comprises polyvinyl-alcohol claim 5 , polyvinyl-styrene claim 5 , or polyacrylate.8. The method of claim 5 , wherein applying the tackifier compound comprises a technique selected from the group consisting of spraying claim 5 , painting claim 5 , filming claim 5 , dip-coating claim 5 , and combinations thereof.9. The method of claim 1 , wherein the inorganic filler particles comprise a ceramic material or a preceramic polymer.10. The method of claim 9 , wherein the ceramic material is formed from a material ...

METHOD OF DESIZING FIBER

A method of preparing a fiber for use in forming a ceramic matrix composite material comprises the steps of removing a polymer coating from an outer surface of glass or ceramic fibers by providing heated and humidified gas across the glass or ceramic fibers for a period of time. 1. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:removing a polymer coating from an outer surface of glass or ceramic fibers by providing heated and humidified gas across said glass or ceramic fibers for a period of time.2. The method as set forth in claim 1 , wherein said glass or ceramic fibers have a diameter of greater than or equal to 5 micron and less than or equal to 150 micron.3. The method as set forth in claim 2 , wherein said gas is heated to a temperature between 20 and 900° C.4. The method as set forth in claim 3 , wherein said gas is heated to between 300 and 500° C.5. The method as set forth in claim 4 , wherein said gas is air.6. The method as set forth in claim 4 , wherein said glass or ceramic fibers include bundled fibers provided with polymer coating on the outer surface.7. The method as set forth in claim 6 , wherein said bundled fibers are provided with a subsequent interface coating after having the polymer coating removed.8. The method as set forth in claim 7 , wherein said subsequent interface coating is provided by a chemical vapor deposition process.9. The method as set forth in claim 7 , wherein said subsequent interface coating includes at least one inner layer and an outer layer.10. The method as set forth in claim 9 , wherein said at least one inner layer of the interface coating is boron nitride.11. The method as set forth in claim 9 , wherein said outer layer of the interface coating is one of silicon nitride claim 9 , silicon carbide claim 9 , boron carbide claim 9 , carbon claim 9 , and combinations thereof.12. The method as set forth in claim 1 , wherein the glass or ceramic fibers are woven ...

Qualification and repair station

Apparatus for qualification and repair of multi-filament tow are provided herein. In some embodiments, an apparatus in for inspecting and repairing a multi-filament tow includes a first spool having a multi-filament tow wound on the first spool; a first tow tensioner following the first spool to impart a predetermined tension on the multi-filament tow; a de-sizing chamber comprising a heater to heat the multi-filament tow to a first temperature suitable for removing a coating on the multi-filament tow; an inspection chamber configured to inspect the multi-filament tow for defects; a repair chamber configured to repair the defects in the multi-filament tow; a second tow tensioner following the repair chamber to impart a predetermined tension on the multi-filament tow; and a second spool following the second tow tensioner to collect the multi-filament tow.

METHODS AND APPARATUS FOR DEPOSITING MATERIALS ON A CONTINUOUS SUBSTRATE

Methods and apparatus for depositing material on a continuous substrate are provided herein. In some embodiments, an apparatus for processing a continuous substrate includes: a first chamber having a first volume; a second chamber having a second volume fluidly coupled to the first volume; and a plurality of process chambers, each having a process volume defining a processing path between the first chamber and the second chamber, wherein the process volume of each process chamber is fluidly coupled to each other, to the first volume, and to the second volume, and wherein the first chamber, the second chamber, and the plurality of process chambers are configured to process a continuous substrate that extends from the first chamber, through the plurality of process chambers, and to the second chamber.

Ceramic matrix composite

A novel ceramic matrix composite is disclosed for forming components that are operable in high temperature environments such those in gas turbine engines and the like. The ceramic matrix composite can include at least one layer of non-crimped fibers positioned substantially parallel to one another. A relatively small diameter elastic fiber can be constructed to stitch the non-crimped fibers together and a ceramic matrix may be deposited around the at least one layer of non-crimped fibers.

ARTICLE HAVING COATING INCLUDING COMPOUND OF ALUMINUM, BORON AND NITROGEN

An article includes a monolithic substrate and a coating on the monolithic substrate. The monolithic substrate is selected from graphite, silicon carbide, silicon carbide nitride, silicon nitride carbide, and silicon nitride. The coating has a free, exposed surface and includes a compound of aluminum (Al), boron (B) and nitrogen (N) in a continuous chemically bonded network having Al—N bonds and B—N bonds. The compound includes an atom of nitrogen covalently bonded to an atom of boron and an atom of aluminum, and the compound has a composition BAlN, where x is 0.001 to 0.999. 1. An article comprising:a monolithic substrate selected from the group consisting of graphite, silicon carbide, silicon carbide nitride, silicon nitride carbide, and silicon nitride; and{'sub': x', '(1-x), 'a coating on the monolithic substrate, the coating having a free, exposed surface and including a compound of aluminum (Al), boron (B) and nitrogen (N) in a continuous chemically bonded network having Al—N bonds and B—N bonds, wherein the compound includes an atom of nitrogen covalently bonded to an atom of boron and an atom of aluminum, and the compound has a composition BAlN, where x is 0.001 to 0.999.'}2. The article as recited in claim 1 , wherein the coating and the monolithic substrate are covalently bonded together.3. The article as recited in claim 2 , wherein the monolithic substrate is silicon carbide.4. The article as recited in claim 1 , wherein the coating includes an amount of B—N claim 1 , by weight claim 1 , of no greater than 50%.5. The article as recited in claim 1 , wherein the coating includes an amount of B—N claim 1 , by weight claim 1 , of no greater than 10%.6. The article as recited in claim 1 , wherein the Al—N and B—N are dispersed in the coating as of domains of Al—N and B—N that have an average maximum domain size of one-hundred nanometers or less.7. The article as recited in claim 6 , wherein the Al—N and B—N are in a ratio claim 6 , by weight claim 6 , of 90: ...