Surface treatments for ceramic coated/impregnated materials

A method of forming a fabric-reinforced ceramic matrix composite article, the method comprising:

• providing a prepreg composite comprising one or more layers of infiltrated fabric, wherein the infiltrated fabric comprises inorganic fabric infiltrated with a first slurry mixture comprising an oxide component and a liquid media, and wherein the one or more layers of the infiltrated fabric have a pre-infiltration thickness of from about 5 mm to about 75 mm prior to being infiltrated with the first slurry mixture;
• contacting the prepreg composite with a surface of a preform;
• applying an infiltrated paper to at least one surface of the prepreg composite to form a surface-treated prepreg composite, wherein the infiltrated paper comprises inorganic paper infiltrated with a second slurry mixture comprising an oxide component and a liquid media, and wherein the infiltrated paper has a thickness of from about 0.1 mm to about 4.99 mm prior to being infiltrated with the second slurry mixture;
• and
• sintering the surface-treated prepreg composite at a sintering temperature of from about 700° C. to about 1400° C. to form the fabric-reinforced ceramic matrix composite article,
• wherein the infiltrated paper includes non-woven, randomly oriented inorganic fibers that provide structural reinforcement in surface-treated prepreg composites and layups thereof where these inorganic fibers may take the form of chopped fibers, continuous fibers, filaments, tows, bundles, sheets, plies, or any combination thereof.

The method of any one of claims, 26-27, 28, 29, or 30, wherein the first slurry mixture and/or the second slurry mixture is an aqueous slurry mixture comprising:

• from about 0.1 wt % to about 40 wt % colloidal silica;
• from about 0.1 wt % to about 10 wt % liquid media soluble polymer;
• from about 40 wt % to about 85 wt % aluminum oxide powder;
• and
• from about 10 wt % to about 60 wt % water.

A method of forming a fabric-reinforced ceramic matrix composite article, the method comprising:

• providing a prepreg composite comprising one or more layers of infiltrated fabric, wherein the infiltrated fabric comprises inorganic fabric infiltrated with a first slurry mixture comprising an oxide component and a liquid media, and wherein the one or more layers of the infiltrated fabric have a pre-infiltration thickness of from about 5 mm to about 75 mm prior to being infiltrated with the first slurry mixture;
• contacting the prepreg composite with a surface of a preform;
• applying an infiltrated paper to at least one surface of the prepreg composite to form a surface-treated prepreg composite, wherein the infiltrated paper comprises inorganic paper infiltrated with a second slurry mixture comprising an oxide component and a liquid media, and wherein the infiltrated paper has a thickness of from about 0.1 mm to about 4.99 mm prior to being infiltrated with the second slurry mixture;
• curing the surface-treated prepreg composite at a pressure of from about 10 psi to about 200 psi and at a temperature of from about 75° C. to about 500° C.;
• and
• sintering the surface-treated prepreg composite at a sintering temperature of from about 700° C. to about 1400° C. to form the fabric-reinforced ceramic matrix composite article,
• wherein the infiltrated paper includes non-woven, randomly oriented inorganic fibers that provide structural reinforcement in surface-treated prepreg composites and layups thereof where these inorganic fibers may take the form of chopped fibers, continuous fibers, filaments, tows, bundles, sheets, plies, or any combination thereof.

A method of forming a fabric-reinforced ceramic matrix composite article, the method comprising:

• providing a prepreg composite comprising one or more layers of infiltrated fabric, wherein the infiltrated fabric comprises inorganic fabric infiltrated with a first slurry mixture comprising an oxide component and a liquid media, and wherein the one or more layers of the infiltrated fabric have a pre-infiltration thickness of from about 5 mm to about 75 mm prior to being infiltrated with the first slurry mixture;
• curing the prepreg composite at a pressure of from about 10 psi to about 200 psi and at a temperature of from about 75° C. to about 500° C. to form a cured prepreg composite;
• and
• applying an infiltrated paper to at least one surface of the cured prepreg composite to form a surface-treated prepreg composite, wherein the infiltrated paper comprises inorganic paper infiltrated with a second slurry mixture comprising an oxide component and a liquid media, and wherein the infiltrated paper has a thickness of from about 0.1 mm to about 4.99 mm prior to being infiltrated with the second slurry mixture;
• and
• sintering the surface-treated prepreg composite at a sintering temperature of from about 700° C. to about 1400° C. to form the fabric-reinforced ceramic matrix composite article,
• wherein the infiltrated paper includes non-woven, randomly oriented inorganic fibers that provide structural reinforcement in surface-treated prepreg composites and layups thereof where these inorganic fibers may take the form of chopped fibers, continuous fibers, filaments, tows, bundles, sheets, plies, or any combination thereof.