Filament winding apparatus and method for ceramic matrix composites

An apparatus for making a composite article, the apparatus comprising:

• a monofilament feed track adapted to carry a first spaced array of ceramic monofilament strands;
• a fiber yarn feed track adapted to carry a second spaced array of fiber yarn tows impregnated with a plurality of glass particulates;
• a mandrel disposed at an end of the monofilament feed track and an end of the fiber yarn feed track, the mandrel adapted to wind together individual tows of the first spaced array of glass-impregnated fiber yarn tows and individual strands of the array of ceramic monofilament strands to form a dual-fiber weave;
• and
• a heater assembly disposed within or adjacent to the mandrel, the heater assembly adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC);
• wherein the monofilament feed track comprises:
• a plurality of monofilament spools configured to provide a first tension of at least 430 MPa to each of a corresponding plurality of ceramic monofilament strands on each spool;
• and
• a collimator disposed along the monofilament feed track between the plurality of monofilament spools and the mandrel;
• and
• wherein the fiber yarn feed track comprises:
• a plurality of fiber yarn spools having a corresponding plurality of fiber yarn tows;
• and
• a slurry tank disposed along the fiber yarn feed track between the plurality of fiber yarn spools and the mandrel;
• wherein the slurry tank is adapted to receive only unspooled ones of the fiber yarn strands at a second tension less than the first tension.