Composites and methods of forming composites having an increased volume of oxidation resistant ceramic particles
AssigneeGoodrich Corporation
InventorChristopher T. Kirkpatrick
Life of this patent
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Abstract
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 performing a silicon melt infiltration after the densification process. A plurality of pores defined by the carbon matrix material are infiltrated with a silicon material and the fibrous preform is heated to a melt temperature until a desired percentage (e.g., at least 50%) of the carbon matrix material is converted into silicon carbide or another oxidation resistant material.
Claims14
A method of fabricating a composite component, comprising:
- forming a fibrous preform by:
- forming a first ceramic particle layer over a first textile layer by depositing a mixture of silicon carbide powder and phenolic resin powder over the 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;
- performing a densification process on the fibrous preform, the densification process including coating a plurality of fibers of the fibrous preform with a carbon matrix material;
- and
- performing a silicon melt infiltration process after the densification process, the silicon melt infiltration process including:
- infiltrating a plurality of pores defined by the carbon matrix material with a silicon material, and
- heating the fibrous preform to a melt temperature until at least 50% of the carbon matrix material and at least a portion of the silicon material are converted into silicon carbide.
A method of forming a fibrous preform for fabricating a composite component, comprising:
- forming a first ceramic particle layer over a first textile layer, the first ceramic particle layer comprising a first volume of silicon carbide powder having an average particle size between 35 micrometers and 163 micrometers, and the first textile layer comprising pre-oxidized stretch-broken carbon fibers,
- disposing a second textile layer over the first ceramic particle layer;
- forming a second ceramic particle layer over the second textile layer;
- disposing a third textile layer over the second ceramic particle layer;
- coating at least one of the first ceramic particle layer, the first textile layer, the second textile layer, the second ceramic particle layer, or the third textile layer with a carbon matrix material;
- infiltrating a plurality of pores defined by the carbon matrix material with a silicon material;
- and
- heating the composite component to a melt temperature until at least 50% of the carbon matrix material and at least a portion of the silicon material are converted into a silicon carbide.
Dependencies are inferred from the claim text.