Reaction controlled melt-infiltrated fabrication of ceramic matrix composites

A melt-infiltrated ceramic matrix composite fabricated according to the steps comprising:

• fabricating a ceramic fiber preform comprising at least one fiber, at least one fiber tow, or at least one fiber and fiber tow;
• optionally depositing at least one interface coating on the at least one fiber, the at least one fiber tow, or the at least one fiber and fiber tow;
• depositing at least one structural support material coating on the at least one fiber, the at least one fiber tow, or the at least one fiber and fiber tow to form a partially densified ceramic matrix composite comprising at least one pore, at least one porous network or at least one pore and porous network;
• depositing at least one fiber protection material coating on the at least one fiber, the at least one fiber tow, or the at least one fiber and fiber tow;
• infiltrating a slurry composition comprising at least one sacrificial particle into the at least one pore, the at least one porous network or both the at least one pore and the porous network;
• depositing at least one reaction control material coating on the at least one fiber, the at least one fiber tow, or the at least one fiber and fiber tow of the partially densified ceramic matrix composite;
• optionally depositing at least one wetting layer coating on the at least one reaction control material coating of the partially densified ceramic matrix composite, the at least one reaction control material coating of the at least one sacrificial particle, or both the at least one reaction control material coating of the partially densified ceramic matrix composite and the at least one reaction control material coating of the at least one sacrificial particle;
• melt-infiltrating at least one molten infiltrant into the partially densified ceramic matrix composite to form a melt-infiltrated ceramic matrix composite;
• and
• optionally heat treating the melt-infiltrated ceramic matrix composite,
• wherein the at least one sacrificial particle comprises a core, at least one reaction control material coating disposed adjacent the core, and the optional at least one wetting layer coating disposed adjacent the at least one reaction control material coating and opposite the core.

A process for fabricating a melt-infiltrated ceramic matrix composite, comprising the steps of:

• fabricating a ceramic fiber preform comprising at least one fiber, at least one fiber tow, or at least one fiber and fiber tow;
• optionally depositing at least one interface coating on the at least one fiber, the at least one fiber tow, or the at least one fiber and fiber tow;
• depositing at least one structural support material coating on the at least one fiber, the at least one fiber tow, or the at least one fiber and fiber tow to form a partially densified ceramic matrix composite comprising at least one pore, at least one porous network or both the at least one pore and the porous network;
• depositing at least one fiber protection material coating on the at least one fiber, the at least one fiber tow, or the at least one fiber and fiber tow;
• infiltrating a slurry composition comprising at least one coated sacrificial particle into the at least one pore, the at least one porous network or the at least one pore and porous network;
• melt-infiltrating at least one molten infiltrant into the partially densified ceramic matrix composite to form a melt-infiltrated ceramic matrix composite;
• and
• optionally heat treating the melt-infiltrated ceramic matrix composite.