Method of forming fiber- and filament-containing ceramic preform and composite

A process for producing a compact comprised of a mixture of fibers and particulates surrounding a layer of continuous filaments which comprises preparing a suspension of ceramic material in a liquid vehicle, said ceramic material being comprised of a mixture of fibers and particulates, said fibers being discontinuous and having an aspect ratio ranging from about 10 to less than about 200, said particulates having an equivalent diameter ranging from greater than about 0.2.mu. to less than about 3.mu., the volume ratio of said fibers to said particulates ranging from about 1:5 to about 1:1, at least about 90% by volume of said particulates being filler particulates, said ceramic material being present in an amount greater than about 4% by volume of said suspension, said ceramic fibers being present in an amount greater than about 2% by volume of said suspension, removing a sufficient portion of said liquid vehicle to leave a moldable ceramic mass, molding part of said moldable ceramic mass producing ceramic layers of said compact, depositing a layer of a plurality of continuous filaments on a first layer of compact with said filaments being positioned substantially parallel to each other and extending at least substantially across said first layer of compact, said filaments having a melting or decomposition point higher than 1000.degree. C., depositing a second ceramic layer over said filaments forming substantially a sandwich structure with said first layer, and pressing said second ceramic layer causing it to adhere and embed said filaments producing said compact, said filaments having been maintained substantially in said position, said fibers and filler particulates being selected from the group consisting of aluminum oxide, beryllium oxide, silicon carbide, silicon nitride, titanium carbide, titanium diboride, zirconium carbide, zirconium diboride, and a mixture thereof, from 0 to about 10% by volume of said particulates being comprised of a ceramic meltable material which has a melting point ranging from a minimum of about 1000.degree. C. to a maximum which is about 100.degree. C. below the melting or decomposition point of said fibers, filler particulates and filaments and in its molten state wets said fibers, filler particulates and filaments.

A process for preparing a compact which comprises preparing a suspension comprised of ceramic material suspended in a liquid vehicle, said ceramic material being comprised of a mixture of fibers and particulates, said fibers being discontinuous and having an aspect ratio ranging from about 10 to less than about 200, said particulates having an equivalent diameter ranging from greater than about 0.2.mu. to less than about 3.mu., the volume ratio of said fibers to said particulates ranging from about 1:5 to about 1:1, at least about 90% by volume of said particulates being filler particulates, said ceramic material being present in an amount greater than about 4% by volume of said suspension, said ceramic fibers being present in an amount greater than about 2% by volume of said suspension, taking a part of said suspension and removing a sufficient portion of said liquid vehicle therefrom to leave a moldable ceramic mass, molding said moldable ceramic mass into a first ceramic layer of said compact, depositing a layer of a plurality of continuous ceramic filaments on said first layer of compact with said filaments being positioned substantially parallel to each other and extending at least substantially across said first ceramic layer, said filaments having a melting or decomposition point higher than 1000.degree. C., depositing a sufficient amount of said suspension on said filaments and removing sufficient vehicle to produce a second ceramic layer of said compact which covers said filaments and produces said compact, said filaments having been maintained substantially in said position, said fibers and filler particulates being selected from the group consisting of aluminum oxide, beryllium oxide, silicon carbide, silicon nitride, titanium carbide, titanium diboride, zirconium carbide, zirconium diboride and a mixture thereof, from 0 to about 10% by volume of said particulates being comprised of a ceramic meltable material which has a melting point ranging from a minimum of about 1000.degree. C. to a maximum which is about 100.degree. C. below the melting or decomposition point of said fibers, filler particulates and filaments and in its molten state wets said fibers, filler particulates and filaments.