Method of obtaining a fiber-containing composite

A process for producing a composite with a porosity of less than about 20% by volume comprised of boron nitride-coated fibrous material and a matrix phase, said fibrous material component of said coated fibrous material comprising at least about 5% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps:

• (a) depositing boron nitride on a carboncontaining fibrous material producing a coating thereon which leaves no significant portion of said fibrous material exposed;
• (b) depositing a silicon-wettable material on said boron nitride-coated fibrous material producing a coating thereon which leaves no significant portion of said boron nitride exposed;
• (c) admixing an infiltration-promoting material containing elemental carbon with the resulting coated fibrous material producing a mixture wherein the fibrous material component of said coated fibrous material comprises at least about 5% by volume of said mixture;
• (d) forming said mixture into a preform having an open porosity ranging from about 25% by volume to about 90% by volume of the preform;
• (e) providing an infiltrant composition comprised of boron and silicon wherein boron ranges from about 0.1% by weight to about 10% by weight of elemental silicon;
• (f) contacting said preform and said infiltrant composition with infiltrating means whereby molten infiltrant is infiltrated into said preform;
• (g) heating the resulting structure to a temperature at which said infiltrant composition is molten resulting in a molten infiltrant containing elemental boron in solution in an amount ranging from about 0.1% by weight of silicon to an amount which forms a saturated solution with silicon and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite;
• and
• (h) cooling said product to produce said composite.

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated fibrous material and a matrix phase, said fibrous material component of said coated fibrous material comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boroncontaining silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps:

• (a) depositing boron nitride on a carbon-containing fibrous material producing a coating thereon which leaves no significant portion of said fibrous material exposed;
• (b) depositing a silicon-wettable material on said boron nitride-coated fibrous material producing a coating thereon which leaves no significant portion of said boron nitride exposed;
• (c) admixing an infiltration-promoting material containing elemental carbon with the resulting coated fibrous material producing a mixture wherein the fibrous material component of said coated fibrous material comprises at least about 5% by volume of said mixture and is sufficient to produce said composite;
• (d) forming said mixture into a preform having an open porosity ranging from about 35% by volume to about 80% by volume of the preform;
• (e) providing an infiltrant comprises of boron and silicon wherein boron ranges from about 1% by weight to about 3% by weight of elemental silicon and contains boron in solution in an amount ranging from about 1% by weight of silicon to an amount which forms a saturated solution with silicon;
• (f) contacting said preform with infiltrant-associated infiltrating means whereby said infiltrant is infiltrated into said preform;
• (g) heating the resulting structure to a temperature at which said infiltrant is molten and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite;
• and
• (h) cooling said product to produce said composite.