HYBRED POLYMER CVI COMPOSITES

• US 20110071014A1
• Filed: 09/24/2009
• Published: 03/24/2011
• Est. Priority Date: 09/24/2009
• Status: Abandoned Application

• Current Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Newton, Kirk C., Kmetz, Michael A.
• Application Number:
  US12/566,339
• Publication Number:
  US 20110071014A1
• Time in Patent Office: Days
• US Class Current: 501/95.2
• CPC Class Codes: C04B 2235/3826 Silicon carbides
• CPC Class Codes: C04B 2235/3878 Alpha silicon nitrides
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/608 Green bodies or pre-forms with well-defined density
• 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 2235/77 Density
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/571 obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/584 based on silicon nitride
• CPC Class Codes: C04B 35/589 obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/622 Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• CPC Class Codes: C04B 35/62868 Boron nitride
• CPC Class Codes: C04B 35/62871 Silicon nitride
• CPC Class Codes: C04B 35/62894 with more than one coating layer
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C23C 16/045 Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates

Abstract

A method of forming a highly densified chemical matrix composite CMC from a preform of a matrix of a non-oxide ceramic and continuous ceramic fibers. An interface coating is added, followed by partially densifying the preform with a resin to increase the density of the preform using a polymer infiltration pyrolysis PIP) process one or more times. A chemical vapor infiltration (CVI) process is used to bring the CMC to a final desired density.

Claims

1. A method of forming a highly densified ceramic matrix composite (CMC), comprising:

forming a preform of a matrix formed from a non-oxide ceramic and continuous ceramic fibers and adding an interface coating;

partially densifying the preform with a resin to increase the density of the preform using a polymer infiltration pyrolysis (PIP) process; and

infiltrating the preform using a chemical vapor infiltration process (CVI) to a final density.

2. The method of claim 1, wherein the preform is formed from a plurality of layers of a ceramic fiber impregnated with a resin the plurality of layers being layed-up on a predetermined orientation to form a green composite having desired shape.

3. The method of claim 2, wherein the impregnated resin is decomposed to form ceramic char.

4. The method of claim 3, wherein the green composite is impregnated and decomposed a plurality of times to form a densified preform.

5. The method of claim 4, wherein the preform is infiltrated by the CVI process to increase the density and reduce porosity of the CMC composite.

6. The method of claim 1, wherein the non-oxide ceramic is selected from the group consisting of silicon carbide, silicon nitride, silicon carbo-nitride and mixtures thereof.

7. The method of claim 1, wherein the ceramic fiber is formed from continuous silicon carbide fiber.

8. The method of claim 1 wherein the composite has a final density of at least 90% of theoretical.

9. A method of forming a highly densified ceramic matrix composite (CMC) composite, comprising:

forming a preform from a plurality of layers of a ceramic fiber impregnated with a resin the plurality of layers being layed-up on a predetermined orientation to form a green composite having desired shape;

partially densifying the preform with a resin to increase the density of the preform using a polymer infiltration pyrolysis (PIP) process decompose to form ceramic char; and

infiltrating the preform using a process chemical vapor infiltration (CVI) process to a finally density of at least 95% of theoretical.

10. The method of claim 9, wherein the green composite is impregnated and decomposed a plurality of times to form a densified preform.

11. The method of claim 10, wherein the preform is infiltrated by the CVI process to increase the density and reduce porosity of the CMC composite.

12. The method of claim 9, wherein the non-oxide ceramic is selected from the group consisting of silicon carbide, silicon nitride, silicon carbo-nitride and mixtures thereof.

13. The method of claim 9, wherein the ceramic fiber is formed from continuous silicon carbide fiber.

14. A highly densified ceramic matrix composite (CMC) having a final density formed by:

forming a preform of a matrix formed from a non-oxide ceramic and continuous ceramic fibers and adding an interface coating;

partially densifying the preform with a resin to increase the density of the preform using a polymer infiltration pyrolysis (PIP) process; and

infiltrating the preform using a chemical vapor infiltration (CVI) process to a final density.

15. The composite of claim 14, wherein the preform is formed from a plurality of layers of a ceramic fiber impregnated with a resin the plurality of layers being layed-up on a predetermined orientation to form a green composite having desired shape.

16. The composite of claim 14, wherein the densifying resin is decompose to form ceramic char.

17. The composite of claim 16, wherein the green composite is impregnated and decomposed a plurality of times to form a densified preform.

18. The composite of claim 17, wherein the preform is infiltrated by the CVI process to increase the density and reduce porosity of the CMC composite.

19. The composite of claim 14, wherein the non-oxide ceramic is selected from the group consisting of silicon carbide, silicon nitride, silicon carbo-nitride and mixtures thereof.

20. The composite of claim 14, wherein the ceramic fiber is formed from continuous silicon carbide fiber.