Additive manufacturing of fiber-reinforced composites with refractory matrix materials

Abstract

A method for the manufacture of fiber-reinforced three-dimensional objects using a refractory matrix material is described. The method includes the additive manufacturing of a green body from a powder-based refractory matrix material, followed by optional partial strengthening, followed by continuous fiber incorporation and reinforcement, followed by full densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic or a refractory metal. The refractory matrix material is deposited according to a binder-jet printing process to produce a green body. The next strengthening step delivers a part ideal for handling. The part is then reinforced with continuous fiber via winding, braiding, or other method of attaching continuous fiber to the part. The composite part then undergoes a CVI step to achieve maximum density and a hermetic seal on all surfaces. Accordingly, complex refractory objects with improved mechanical integrity and toughness can be produced.

Dependencies are inferred from the claim text.