Oxidation protection for carbon-carbon composites

Patent metadata

Field	Value
Publication number	US-10399908-B2
Application number	US-201615352165-A
Country	US
Kind code	B2
Filing date	Nov 15, 2016
Priority date	Nov 15, 2016
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

The method may include forming fibers with a silicon-based sizing, forming a fibrous preform from the fibers, forming a silicon dioxide coating around the fibers, carbonizing the fibrous preform, and densifying the fibrous preform. In various embodiments, forming the fibers with the silicon-based sizing includes utilizing a mass of the silicon-based sizing that is at least 1.0% of a mass of the fibers.

First claim

What is claimed is:

1. A method of manufacturing a carbon-carbon composite material, the method comprising:
forming fibers with a silicon-based sizing, wherein forming the fibers with the silicon-based sizing comprises applying at least one of elemental silicon and silicon compounds over the fibers;
forming a fibrous preform from the fibers;
forming a silicon dioxide coating around the fibers, wherein the silicon dioxide coating is formed from the at least one of elemental silicon and silicon compounds applied over the fibers;
carbonizing the fibrous preform; and
densifying the fibrous preform;
wherein forming the fibers with the silicon-based sizing is performed before forming the silicon dioxide coating around the fibers, before carbonizing the fibrous preform, and before densifying the fibrous preform.

2. The method of claim 1 , wherein forming the fibers with the silicon-based sizing comprises utilizing a mass of the silicon-based sizing that is at least 1.0% of a mass of the fibers.

3. The method of claim 1 , wherein forming the fibers with the silicon-based sizing comprises utilizing a mass of the silicon-based sizing that is between about 1.0% and about 10% of a mass of the fibers.

4. The method of claim 1 , wherein forming the fibers with the silicon-based sizing comprises utilizing a mass of the silicon-based sizing that is between about 1.0% and about 5.0% of a mass of the fibers.

5. The method of claim 1 , wherein forming the fibers with the silicon-based sizing comprises utilizing a mass of the silicon-based sizing that is between about 1.0% and about 4.0% of a mass of the fibers.

6. The method of claim 1 , wherein forming the fibers with the silicon-based sizing comprises utilizing a mass of the silicon-based sizing that is between about 1.0% and about 3.5% of a mass of the fibers.

7. The method of claim 1 , further comprising applying an external oxidation protection coating after densifying the fibrous preform.

8. The method of claim 1 , wherein forming the silicon dioxide coating around the fibers occurs during carbonizing the fibrous preform.

9. The method of claim 8 , wherein carbonizing the fibrous preform is performed with oxygen present.

10. The method of claim 8 , wherein forming the silicon dioxide coating around the fibers occurs during densifying the fibrous preform.

11. The method of claim 1 , wherein forming the silicon dioxide coating around the fibers occurs during densifying the fibrous preform.

12. The method of claim 1 , wherein forming the silicon dioxide coating around the fibers occurs after carbonizing the fibrous preform.

13. The method of claim 1 , wherein forming the fibers with the silicon-based sizing comprises using oxidized polyacrylonitrile fibers.

14. The method of claim 1 , wherein forming the silicon dioxide coating around the fibers comprises encompassing the carbon fibers at a fiber-matrix interface.

15. A method of manufacturing a carbon-carbon composite material, the method comprising:
forming oxidized polyacrylonitrile fibers (“OPF’) with a silicon-based sizing, wherein a mass of the silicon-based sizing is between about 1.5% and about 5.0% of a mass of the OPF, wherein forming the OPF with the silicon-based sizing comprises applying at least one of elemental silicon and silicon compounds over the OPF;
forming a fibrous preform from the OPF;
forming a silicon dioxide coating around the OPF;
carbonizing the fibrous preform; and
densifying the fibrous preform;
wherein forming the OPF with the silicon-based sizing is performed before forming the silicon dioxide coating around the OPF, before carbonizing the fibrous preform, and before densifying the fibrous preform.

16. The method of claim 15 , wherein the mass of the silicon-based sizing is between about 2.0% and about 4.0% of the mass of the OPF.

17. The method of claim 15 , further comprising applying an external oxidation protection coating after densifying the fibrous preform.

18. The method of claim 15 , wherein forming the silicon dioxide coating around the OPF occurs during carbonizing the fibrous preform.

19. The method of claim 18 , wherein carbonizing the fibrous preform is performed with oxygen present.

20. A method of manufacturing a carbon-carbon composite material, the method comprising:
forming oxidized polyacrylonitrile fibers (“OPF’) with a silicon-based sizing, wherein a mass of the silicon-based sizing is between about 2.0% and about 4.0% of a mass of the OPF, wherein forming the OPF with the silicon-based sizing comprises applying at least one of elemental silicon and silicon compounds over the OPF;
forming a fibrous preform from the OPF;
carbonizing the fibrous preform;
during carbonizing the fibrous preform, forming a silicon dioxide coating around the OPF; and
densifying the fibrous preform;
wherein forming the OPF with the silicon-based sizing is performed before carbonizing the fibrous preform, before forming the silicon dioxide coating around the OPF, and before densifying the fibrous preform.

Assignees

• Goodrich Corp

Inventors

• Poteet Steven
• Linck John
• Lu Weiming

Classifications

• C04B35/62878

  with boron or silicon · CPC title

• C04B2235/614

  Gas infiltration of green bodies or pre-forms · CPC title

• C04B35/62272

  based on non-oxide ceramics (carbon nanotubes C01B32/15; carbon fibers D01F9/12) · CPC title

• C04B2235/5248

  Carbon, e.g. graphite · CPC title

• C04B2235/5232

  Silica or silicates other than aluminosilicates, e.g. quartz · CPC title