Structural ceramic materials having refractory interface layers
AssigneeKaiser Aerotech
InventorsShih-Huei Chen, H. O. Davis
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Abstract
Ceramic composite articles having high flexural and tensile strength are produced by introducing multiple layers of a ceramic matrix material onto a ceramic reinforcement fabric. Crack propagation in the resulting structure is inhibited by applying refractory interface layers intermediate successive ceramic matrix layers. Such ceramic composite articles are particularly useful for high temperature applications requiring a high degree of strength, such as rocket motor insulation and turbine blades, combustion chambers, and after burners for jet motors.
Claims57
A process for forming ceramic composite articles, said process comprising:
- (a) introducing a ceramic precursor material onto a reinforcement fabric substrate;
- (b) curing the ceramic precursor;
- (c) converting the cured ceramic precursor material to a ceramic matrix layer by pyrolysis in an inert atmosphere at a pressure below about 50 psi;
- (d) applying a refractory interface layer over the converted ceramic matrix layer;
- and
- (e) densifying the article by repeating steps (a) through (d) until a desired density is achieved.
An improved process for forming ceramic composite articles of the type wherein a plurality of ceramic matrix layers are formed over a reinforcement fabric substrate, said improvement comprising applying a refractory interface layer between successive ceramic reinforcement layers, wherein there are at least two such successive ceramic reinforcement layers.
A ceramic composite article comprising a reinforcement fabric, a plurality of ceramic matrix layers formed over the reinforcement fabric, and a refractory interface layer between at least some of the successive pairs of ceramic matrix layers.
A process for forming ceramic composite articles, said process comprising:
- introducing a liquid polycarbosilane onto a reinforcement fabric substrate;
- curing the polycarbosilane at an elevated temperature under non-oxidizing conditions;
- and
- converting the cured polycarbosilane to silicon carbide by pyrolysis in an inert atmosphere at a pressure below about 50 psi.
A process for forming ceramic composite articles, said process comprising:
- (a) forming a refractory interface layer on a reinforcement fabric;
- (b) introducing a liquid polycarbosilane onto the reinforcement fabric over the refractory interface layer;
- (c) curing the polycarbosilane at an elevated temperature under non-oxidizing conditions;
- (d) converting the cured polycarbosilane to silicon carbide by pyrolysis at a temperature below about 50 psi;
- and
- (e) densifying the article by repeating steps (a) through (d) until a desired density is achieved.
A ceramic composite article comprising a reinforcement fabric and a silicon carbide matrix, wherein the silicon carbide matrix is characterized by alternate silicon carbide layers and refractory interface layers.
Dependencies are inferred from the claim text.