Controlled fiber distribution technique for glass matrix composites

A method for manufacturing a discontinuous fiber reinforced glass matrix composite comprising:

• (a) impregnating continuous multifilament silicon carbide, alumina, silicon nitride or carbon fiber yarn with a slurry comprising glass, glass-ceramic powder or a mixture thereof and a carrier liquid, followed by drying to remove the carrier liquid;
• (b) chopping said impregnated multifilament yarn into discontinuous lengths;
• (c) exposing said chopped impregnated multifilament yarn to a temperature sufficient so that said matrix softens;
• (d) applying a pressure to said heated chopped impregnated multifilament yarn sufficient to displace said heated chopped impregnated multifilament yarn into a mold through an injection nozzle contoured such that sufficient die-wall shear forces are generated to separate substantially all of said multifilament yarn into individual filaments;
• (e) said injection nozzle having a diameter less than the length of said yarn and said injection nozzle having a length greater than said length of said yarn;
• and
• (f) maintaining a mold pressure sufficient to prevent relaxation of the composite until the strain point of the glass is reached;
• resulting in a composite having greater crack resistance.