Method for processing silicon-carbide materials using organic film formers

• US 20040067316A1
• Filed: 10/04/2002
• Published: 04/08/2004
• Est. Priority Date: 10/04/2002
• Status: Abandoned Application

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Gray, Paul, Landlni, Dennis, Matsumoto, Roger Lee Ken
• Application Number:
  US10/263,724
• Publication Number:
  US 20040067316A1
• Time in Patent Office: Days
• US Class Current: 427/376.1
• CPC Class Codes: C04B 2235/422 Carbon
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 35/573 obtained by reaction sintering or recrystallisation
• CPC Class Codes: C04B 35/591 obtained by reaction sintering
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like

Abstract

A method of processing a porous ceramic preform is disclosed comprising: partially infiltrating interconnected pores of a ceramic preform with an organic fluid, converting the organic fluid on pore surfaces of preform to a carbon film, and injecting silicon into the pores with the carbon film of the preform.

Claims

1. A method of processing a porous ceramic preform comprising:

partially infiltrating interconnected pores of a ceramic preform with an organic fluid,

converting the organic fluid on pore surfaces of preform to a carbon film, and

injecting silicon into the pores with the carbon film of the preform.

2. A method a porous ceramic preform as in claim 1 wherein the organic fluid is in a pool and the preform is placed in the pool of organic fluid.

3. A method as in claim 1 further comprising subjecting the preform to a vacuum while the organic fluid is infiltrating the preform, wherein the fluid boils or foams in said vacuum.

4. A method as in claim 1 wherein the preform is placed in the pool of the organic fluid, and the pool is in a vacuum chamber such that the fluid boils or foams in said vacuum.

5. A method as in claim 1 wherein an organic residue remains on the surfaces of the pores and the pyrolizing of the preform converts the residue into a carbon film.

6. A method as in claim 1 further comprising at least partially treating a fiber preform with a chemical vapor infiltration process to produce the ceramic fiber composite preform, and subsequently infiltrating the pores.

7. A method as in claim 1 wherein the preform has a pore volume between 10 volume percent and 45 volume percent, before infiltration of the organic fluid.

8. A method as in claim 1 wherein the organic fluid is selected from a group consisting of one or more of liquid corn syrup, molasses, sugar solution and polyester.

9. A method as in claim 1 wherein the preform is a ceramic fiber composite.

10. A process as in claim 1 wherein the ceramic preform is a ceramic polymer preform.