Ceramic matrix composites and methods for producing ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-2016107940-A1
Application number	US-201414204820-A
Country	US
Kind code	A1
Filing date	Mar 11, 2014
Priority date	Mar 15, 2013
Publication date	Apr 21, 2016
Grant date	—

Abstract

A ceramic matrix composite includes a plurality of fibers embedded in a matrix. The composition of the matrix is selected to achieve a desired relationship between the mechanical and thermal properties of the matrix and the fibers.

First claim

1 . A method of producing a ceramic matrix composite, comprising the steps of:
forming a network of fibers; and depositing a matrix material comprising silicon and carbon onto the fibers to form silicon carbide; wherein the depositing the matrix material comprises at least one of the group consisting of (1) depositing substantial amounts of silicon or carbon in excess of silicon carbide stoichiometric amounts, (2) introducing an oxygen containing gas, (3) introducing a halogen gaseous species, (4) introducing an organometallic gaseous species, or (5) a combination thereof.

2 . (canceled)

3 . (canceled)

4 . (canceled)

5 . The method of claim 1 , wherein the matrix material has approximately the same creep resistance as that of the fibers.

6 . (canceled)

7 . The method of claim 1 , further including the step of depositing an interface layer on the fiber network before depositing the matrix material.

8 . The method of claim 7 , wherein the interface layer includes boron nitride.

9 . (canceled)

10 . (canceled)

11 . (canceled)

12 . (canceled)

13 . The method of claim 1 , wherein the matrix material is deposited by chemical vapor infiltration.

14 . (canceled)

15 . (canceled)

16 . The method of claim 1 , further including processing the ceramic matrix composite by polymer infiltration and pyrolysis.

17 . The method of claim 1 , further including processing the ceramic matrix composite by slurry infiltration.

18 . The method of claim 1 , further including processing the ceramic matrix composite by melt infiltration.

19 . (canceled)

20 . (canceled)

21 . The method of claim 1 , wherein the depositing the matrix material comprises depositing silicon in excess of the silicon carbide stoichiometric amount.

22 . The method of claim 21 , wherein an amount of silicon in excess of the silicon carbide stoichiometric amount is at least about 10 atomic percent.

23 . The method of claim 21 , wherein an amount of silicon in excess of the silicon carbide stoichiometric amount is about 10 atomic percent to about 20 atomic percent.

24 . The method of claim 1 , wherein the depositing the matrix material comprises depositing carbon in excess of the silicon carbide stoichiometric amount.

25 . The method of claim 24 , wherein an amount of carbon in excess of the silicon carbide stoichiometric amount is at least about 10 atomic percent.

26 . The method of claim 24 , wherein an amount of carbon in excess of the silicon carbide stoichiometric amount is about 10 atomic percent to about 20 atomic percent.

27 . The method of claim 1 , wherein the matrix material comprises oxygen from introducing an oxygen containing gas during deposition of the matrix material.

28 . The method of claim 1 , wherein the matrix material comprises at least one element of the group consisting of aluminum, zirconium, boron, nitrogen, titanium, niobium, molybdenum, yttrium, ytterbium, or a combination thereof from introducing a halogen gaseous species during deposition of the matrix material.

29 . The method of claim 1 , wherein the matrix material comprises at least one element of the group consisting of aluminum, zirconium, titanium, niobium, molybdenum, yttrium, ytterbium or a combination thereof from introducing an organometallic gaseous species during deposition of the matrix material.

30 . A method of producing a ceramic matrix composite, comprising the steps of:
forming a network of fibers; and depositing a matrix material comprising silicon and carbon onto the fibers to form silicon carbide, wherein the deposited matrix material comprises at least one of the group consisting of 1) an amount of silicon or carbon in excess of silicon carbide stoichiometric amounts, 2) at least one element selected from the group consisting of aluminum, zirconium, boron, nitrogen, titanium, niobium, molybdenum, yttrium, ytterbium, oxygen or a combination thereof, or 3) a combination of (1) and (2).

31 . The method of claim 30 , wherein the deposited matrix material comprises about 0.2% to about 2% of inclusions containing an element selected from the group consisting of oxygen, nitrogen or combination thereof.

32 . The method of claim 30 , wherein the deposited matrix material comprises about 0.05% to about 2% of aluminum containing inclusions.

Assignees

• Rolls Royce Corp

Inventors

• Lazur Andrew J
• Chamberlain Adam L

Classifications

• C04B41/4584 Primary

  Coating or impregnating of particulate or fibrous ceramic material (C04B20/10, C04B35/628 take precedence) · CPC title

• C04B2235/616

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

• C23C16/325

  Silicon carbide · CPC title

• C04B41/5059

  Silicon carbide · CPC title

• C04B2235/386

  Boron nitrides · CPC title