Method for producing high strength ceramic matrix composites
First Claim
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1. A method of making a high strength ceramic matrix composite, the method comprising the steps of:
- forming a fiber preform that is either self supporting or is constrained by a tool for subsequent processing, wherein the fiber preform comprises fibers that each have a diameter and that define a fiber volume;
coating the fiber preform with about 0.1 μ
m to about 5 μ
m of silicon carbide to form a structural coating on the fibers that increases the diameters of the fibers and effectively increasing the fiber volume, wherein the method further comprises cleaning the fiber preform including the fibers after forming the fiber preform and prior to coating the fiber preform to enhance bonding between the fibers and the structural coating;
coating the structural coating of silicon carbide with about 0.05 μ
m to about 2 μ
m boron nitride, carbon or other interface layer to form an interface layer overlying the structural coating; and
coating the interface layer with about 0.2 μ
m to about 40 μ
m of silicon carbide.
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Abstract
A high strength ceramic matrix composite and method for same is provided. A fiber preform is provided that is either self-supporting or is constrained by a tool for subsequent processing. The preform is coated with about 0.1 μm to about 5 μm of silicon carbide. The silicon carbide is coated with about 0.05 μm to about 2 μm boron nitride, carbon, or other interface layer. The interface layer is coated with at least about 0.2 μm to about 40 μm of silicon carbide.
41 Citations
20 Claims
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1. A method of making a high strength ceramic matrix composite, the method comprising the steps of:
-
forming a fiber preform that is either self supporting or is constrained by a tool for subsequent processing, wherein the fiber preform comprises fibers that each have a diameter and that define a fiber volume; coating the fiber preform with about 0.1 μ
m to about 5 μ
m of silicon carbide to form a structural coating on the fibers that increases the diameters of the fibers and effectively increasing the fiber volume, wherein the method further comprises cleaning the fiber preform including the fibers after forming the fiber preform and prior to coating the fiber preform to enhance bonding between the fibers and the structural coating;coating the structural coating of silicon carbide with about 0.05 μ
m to about 2 μ
m boron nitride, carbon or other interface layer to form an interface layer overlying the structural coating; andcoating the interface layer with about 0.2 μ
m to about 40 μ
m of silicon carbide. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of making a high strength ceramic matrix composite, the method comprising the steps of:
-
forming a fiber preform that is either self supporting or is constrained by a tool for subsequent processing, wherein the fiber preform comprises fibers that each have a diameter and that define a fiber volume; coating the fiber preform with about 0.1 μ
m to about 5 μ
m of silicon carbide to form a structural coating on the fibers that increases the diameters of the fibers and effectively increasing the fiber volume, wherein the method further comprises cleaning the fiber preform including the fibers after forming the fiber preform and prior to coating the fiber preform to enhance bonding between the fibers and the structural coating; andcoating the structural coating of silicon carbide with about 0.2 μ
m to about 40 μ
m of silicon carbide. - View Dependent Claims (10, 11, 12, 13, 14, 15)
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16. A method of making a high strength ceramic matrix composite, the method comprising the steps of:
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forming a silicon carbide fiber preform comprising fibers that each have a diameter and that define a fiber volume of about 36% and assembling the silicon carbide fiber preform in a tool for chemical vapor infiltration; coating the silicon carbide fiber preform with about 1 μ
m to about 5 μ
m of silicon carbide to form a structural coating on the fibers that increases the diameters of the fibers and effectively increasing the fiber volume, wherein the method further comprises cleaning the silicon carbide fiber preform including the fibers after forming the silicon carbide fiber preform and prior to coating the silicon carbide fiber preform to enhance bonding between the fibers and the structural coating;coating the structural coating of silicon carbide with about 0.5 μ
m boron nitride interface layer; andcoating the boron nitride interface layer with about 2 μ
m of silicon carbide. - View Dependent Claims (17, 18, 19, 20)
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Specification