Fabric-reinforced ceramic matrix composite material
AssigneeCeracom Technologies, Inc.
InventorDale E. Woolum
Life of this patent
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Abstract
A graphite fabric-reinforced ceramic matrix composite material is fabricated from multiple plies of graphite fabric saturated with a slurry of an aqueous alkali silicate and a powdered ceramic. The slurry-saturated plies, laid up on a pattern, are vacuum-bagged and cured at elevated temperatures, either in an oven, or, in a preferred embodiment, in an autoclave under elevated pressure. In a preferred embodiment, the fibers of the graphite fabric are metal-plated to provide an outer surface metallization for improved bonding with the alkali silicate. The result is a composite material with the mechanical and thermal characteristics necessary for use in molding tools for the fabrication of other structures made of high temperature composite materials.
Claims21
A method of fabricating a fabric-reinforced ceramic matrix composite material, comprising the steps of:
- (a) supplying a pattern with a molding surface;
- (b) coating the molding surface with a mold release composition;
- (c) supplying a mat of graphite strands;
- (d) coating the mat with a first slurry of an aqueous alkali silicate and a ceramic powder;
- (e) applying the coated mat to the molding surface;
- (f) saturating a graphite fabric ply with a second slurry of an aqueous alkali silicate and a ceramic powder;
- (g) laying the saturated graphite fabric ply onto the mat;
- (h) applying a release sheet over the saturated graphite fabric ply;
- (i) applying a sheet of open mesh fabric over the release sheet;
- (j) sealing the mat, the saturated graphite fabric ply, the release sheet, and the sheet of open mesh fabric in an evacuable bag;
- (k) evacuating air from the bag so that atmospheric pressure compresses the layers of material contained therein;
- and
- (l) while maintaining the evacuation of air from the bag, curing the first and second slurries by the application of heat at temperatures of at least approximately 65.degree. C.
A method of fabricating a fabric-reinforced, ceramic matrix composite material, comprising the steps of:
- (a) applying to multiple plies of graphite fiber a slurry of an aqueous alkali silicate and a powdered ceramic;
- (b) laying the multiple plies on top of one another to form an uncured laminate;
- (c) enclosing the uncured laminate in an evacuable bag;
- (d) Evacuating air from the bag so as to compress the uncured laminate by atmospheric pressure;
- and
- (e) while maintaining the evacuation of the bag, curing the laminate by the application of heat at temperatures of at least approximately 65.degree. C.
Dependencies are inferred from the claim text.