Method for combined desizing and interface coating of fibers for ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-10093585-B2
Application number	US-201514712192-A
Country	US
Kind code	B2
Filing date	May 14, 2015
Priority date	Jun 6, 2014
Publication date	Oct 9, 2018
Grant date	Oct 9, 2018

Abstract

A method of preparing a fiber for use in forming a ceramic matrix composite material comprises the steps of removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber, and using the pyrolyzed remnants as a reactant to provide an interface coating on the fiber.

First claim

The invention claimed is:

1. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:
removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber, the pyrolyzed remnants including residual carbon;
using the pyrolyzed remnants as a reactant to provide an interface coating on the fiber; and
performing a heat treatment to create the interface coating, wherein the heat treatment occurs in a vacuum or in nitrogen.

2. The method according to claim 1 wherein the organic sizing comprises a polymer based coating.

3. The method according to claim 1 including providing the heat treatment with a material comprising a solid species that includes at least boron to provide the interface coating.

4. The method according to claim 3 wherein the heat treatment occurs in the vacuum.

5. The method according to claim 4 wherein the heat treatment occurs approximately at 100 mTorr pressure or less.

6. The method according to claim 4 wherein the heat treatment occurs approximately at 1450° Celsius or less.

7. The method according to claim 4 including providing an additional heat treatment in nitrogen to provide a boron carbide, a boron nitride coating, and/or a boron nitride coating that includes carbon.

8. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:
removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber, wherein the organic sizing comprises a polymer based coating, and wherein the polymer based coating further comprises carbon nanotubes; and
using the pyrolyzed remnants as a reactant to provide an interface coating on the fiber.

9. The method according to claim 8 including subsequently forming a layer that includes boron nitride nanotubes.

10. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:
removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber, wherein the organic sizing comprises a polymer based coating, and wherein the polymer based coating further comprises select inorganic additives or catalysts; and
using the pyrolyzed remnants as a reactant to provide an interface coating on the fiber.

11. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:
removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber;
using the pyrolyzed remnants as a reactant to provide an interface coating on the fiber;
performing a heat treatment with a material comprising a solid species that includes at least boron to create the interface coating, and wherein the heat treatment occurs in nitrogen.

12. The method according to claim 11 wherein the heat treatment occurs approximately at 1450° Celsius or less.

13. The method according to claim 11 including providing an additional heat treatment in nitrogen with silicon oxide to provide a boron nitride coating, a boron nitride coating that includes carbon, and/or silicon nitride coating.

14. A method of forming a ceramic matrix composite material comprising the steps of:
removing an organic sizing from a fiber to provide pyrolyzed remnants on the fiber, wherein the pyrolyzed remnants include residual carbon;
using the pyrolyzed remnants as a reactant to provide an interface coating on the fiber;
performing a heat treatment with a boron based solid species to create the interface coating, wherein the heat treatment occurs in a vacuum or in nitrogen; and
forming a ceramic matrix composite from fibers having the interface coating.

15. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:
removing a polymer based sizing from a ceramic fiber to provide residual carbon on the fiber;
using the residual carbon as a reactant to provide an interface coating on the fiber; and
performing a heat treatment to produce the interface coating, wherein the heat treatment occurs in a vacuum.

16. The method according to claim 15 including providing the heat treatment with a boron based solid species to provide the interface coating.

17. The method according to claim 16 wherein the heat treatment occurs in the vacuum approximately at 100 mTorr pressure or less, and at a temperature of approximately 1450° Celsius or less, to form the interface coating as a boron carbide coating.

18. A method of preparing a fiber for use in forming a ceramic matrix composite material comprising the steps of:
removing a polymer based sizing from a ceramic fiber to provide residual carbon on the fiber;
using the residual carbon as a reactant to provide an interface coating on the fiber; and
performing a heat treatment with a boron based solid species to create the interface coating, wherein the heat treatment occurs in nitrogen at a temperature of approximately 1450° Celsius or less to form the interface coating as a boron (carbon) nitrogen coating.

19. The method according to claim 18 including providing an additional heat treatment in nitrogen with silicon oxide, and at a temperature of approximately 1600° Celsius or less, to provide a boron nitride coating, a boron nitride coating that includes carbon, and/or silicon nitride coating.

Assignees

• United Technologies Corp

Inventors

• Sheedy Paul
• Magdefrau Neal

Classifications

• C04B2235/5284

  Hollow fibers, e.g. nanotubes · CPC title

• C04B35/6286

  Carbides · CPC title

• C04B35/62844

  Coating fibres · CPC title

• C04B2235/6581

  Total pressure below 1 atmosphere, e.g. vacuum · CPC title

• C04B2235/524

  Non-oxidic, e.g. borides, carbides, silicides or nitrides · CPC title