Method for producing high strength ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-2016159702-A1
Application number	US-201414204714-A
Country	US
Kind code	A1
Filing date	Mar 11, 2014
Priority date	Mar 15, 2013
Publication date	Jun 9, 2016
Grant date	—

Abstract

A high strength ceramic matrix composite and method for same is provided. A fiber preform is provided that is either self-supporting or is constrained by a tool for subsequent processing. The preform is coated with about 0.1 μm to about 5 μm of silicon carbide. The silicon carbide is coated with about 0.05 μm to about 2 μm boron nitride, carbon, or other interface layer. The interface layer is coated with at least about 0.2 μm to about 40 μm of silicon carbide.

First claim

What is claimed is:

1 . A method of making a high strength ceramic matrix composite, the method comprising the steps of:
i. forming a fiber preform that is either self supporting or is constrained by a tool for subsequent processing; ii. coating the preform with about 0.1 μm to about 5 μm of silicon carbide; iii. coating the silicon carbide with about 0.05 μm to about 2 μm boron nitride, carbon or other interface layer; and iv. coating the interface layer with at least about 0.2 μm to about 40 μm of silicon carbide.

2 . The method of making the high strength ceramic matrix composite of claim 1 , further comprising the step of: forming the fiber preform having a range of about 10% to about 45% fiber volume.

3 . The method of making the high strength ceramic matrix composite of claim 1 , further comprising the step of: forming the fiber preform with a silicon carbide fiber such as but not limited to HiNicalon, HiNicalon S, Tyranno SA3, CefNITE, CG Nicalon, Tyranno ZMI.

4 . The method of making the high strength ceramic matrix composite of claim 1 , wherein the first coating includes one or more of the following elements (by volume); from 0 to 70% silicon, carbon, nitrogen, boron, oxygen, and from 0 to 40% zirconium, titanium, tantalum, hafnium, erbium, ytterbium, dysprosium, gadolinium, niobium, molybdenum, tantalum, Rhenium, Germanium, Tin, or Selenium.

5 . The method of making the high strength ceramic matrix composite of claim 1 , wherein the fiber preform is self supporting having an integrally woven and angled interlock architecture.

6 . The method of making the high strength ceramic matrix composite of claim 1 , further comprising the step of: coating the preform by a method selected from the group consisting of chemical vapor infiltration, physical vapor deposition, and directed vapor deposition.

7 . The method of making the high strength ceramic matrix composite of claim 1 , further comprising the step of: coating the silicon carbide layer that is located over the silicon carbide interface layer with additional layers.

8 . A method of making a high strength ceramic matrix composite, the method comprising the steps of:
i. forming a fiber preform that is either self supporting or is constrained by a tool for subsequent processing; ii. coating the preform with about 0.1 μm to about 5 μm of silicon carbide; and iii. coating the silicon carbide interface layer with at least about 0.2 μm to about 40 μm of silicon carbide.

9 . The method of making the high strength ceramic matrix composite of claim 8 , further comprising the step of: coating the silicon carbide with about 0.5 μm silicon carbide interface layer.

10 . The method of making the high strength ceramic matrix composite of claim 8 , further comprising the step of: forming the fiber preform having a range of about 10% to about 45% fiber volume.

11 . The method of making the high strength ceramic matrix composite of claim 8 , wherein the fiber preform is self supporting having an integrally woven and angled interlock architecture.

12 . The method of making the high strength ceramic matrix composite of claim 8 , further comprising the step of: coating the preform by a method selected from the group consisting of chemical vapor infiltration, physical vapor deposition, and directed vapor deposition.

13 . The method of making the high strength ceramic matrix composite of claim 8 , further comprising the step of: coating the silicon carbide layer that is located over the silicon carbide interface layer with additional layers.

14 . The method of making the high strength ceramic matrix composite of claim 13 , further comprising the step of: completing the composite by applying a process selected from the group consisting of at least one of chemical vapor infiltration, physical vapor deposition, tape casting, particulate infiltration, pre-ceramic polymer infiltration and pyrolysis, and metal infiltration.

15 . A method of making a high strength ceramic matrix composite, the method comprising the steps of:
i. forming a Hi-Nicalon preform composed of about 36% fiber volume and assembled in a tooling for chemical vapor infiltration; ii. coating the Hi-Nicalon preform with about 1 μm to about 5 μm of silicon carbide; iii. coating the silicon carbide with about 0.5 μm boron nitride interface layer; and iv. coating the silicon carbide interface layer with about 2 μm of silicon carbide.

16 . The method of making the high strength ceramic matrix composite of claim 15 , further comprising the step of: completing the ceramic matrix composite through slurry and melt infiltration.

17 . The method of making the high strength ceramic matrix composite of claim 15 , further comprising the step of: coating the Hi-Nicalon preform with about 1 μm to about 5 μm of silicon carbide by chemical vapor infiltration.

18 . The method of making the high strength ceramic matrix composite of claim 15 , further comprising the step of: coating the silicon carbide interface layer with about 2 μm of silicon carbide by chemical vapor infiltration.

19 . The method of making the high strength ceramic matrix composite of claim 8 further comprising the steps of: providing a silicon and carbon fiber coated in tow form with about 2 μm of silicon carbide by chemical vapor deposition; and applying a silicon doped boron nitride coat of about 0.3 μm on to the silicon carbide.

20 . The method of making the high strength ceramic matrix composite of claim 19 , further comprising the steps of: processing the tow with a silicon carbide slurry and binders to form a tape; laminating the tape; shaping the tape; curing the tape forming a body; and infiltrating the body with silicon.

Assignees

• Rolls Royce Corp

Inventors

• Lazur Andrew J

Classifications

• C04B41/87 Primary

  Ceramics · CPC title

• C04B35/565 Primary

  based on silicon carbide · CPC title

• C04B35/80

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• C04B2235/5244

  Silicon carbide · CPC title

• C04B2235/5252

  having a specific pre-form · CPC title