Shape forming OPF preform

A method for manufacturing a C/C part, the method comprising:

• heating a female forming tool and a first member to a shape forming temperature of between 65° C. and 205° C., the female forming tool comprising a metal material, the female forming tool comprising a die recess, the female forming tool extends longitudinally along a longitudinal centerline of the female forming tool between and to a first end of the female forming tool and a second end of the female forming tool, the female forming tool extends laterally between and to a first side of the female forming tool and a second side of the female forming tool, the die recess extends vertically into the female forming tool from a first top surface and a second top surface of the female forming tool to a recess surface of the female forming tool, and the first top surface and the second top surface are arranged on opposing sides of the recess surface at a top side of the female forming tool;
• positioning an oxidized PAN fiber preform with the female forming tool;
• forming the oxidized PAN fiber preform into a shaped body, the forming comprising:
• moving the first member at least partially into the die recess, the first member shaped to be complementary to the die recess and comprising a metal material, the oxidized PAN fiber preform disposed between the first member and the female forming tool;
• compressing the oxidized PAN fiber preform between the first member and the female forming tool, thereby increasing a fiber volume ratio of the oxidized PAN fiber preform;
• bending the oxidized PAN fiber preform over a radii surface of the female forming tool, the radii surface forms a rounded, convex surface transition disposed between a sidewall portion of the recess surface at least partially defining the die recess and the first top surface of the female forming tool;
• and
• clamping the oxidized PAN fiber preform directly between a first grip strip and the female forming tool while the oxidized PAN fiber preform is being compressed between the first member and the female forming tool, the first grip strip is located at the first top surface of the female forming tool and disposed along a periphery of the oxidized PAN fiber preform;
• removing the shaped body from the female forming tool;
• moving the shaped body into a graphite fixture having a contoured shape corresponding to a shape of the die recess of the female forming tool;
• performing a carbonization process on the shaped body at a temperature of greater than about 1600° C. while the shaped body is in the graphite fixture;
• moving the shaped body into a perforated graphite fixture, the perforated graphite fixture having a contoured shape corresponding to a shape of the die recess of the female forming tool and having a graphite paint disposed on contact surfaces;
• depositing carbon on and within the shaped body via a first chemical vapor infiltration process performed at a temperature of between 900° C. to 1100° C. for between about 150 hours and about 650 hours while the shaped body is in the perforated graphite fixture, wherein the contact surfaces are configured to contact the shaped body during the first chemical vapor infiltration process;
• performing a heat treat at a temperature of greater than 1600° C.;
• performing a second chemical vapor infiltration process on the shaped body;
• and
• performing a second heat treat at a temperature of about 1200° C. to about 2600° C.