Processing method for pip derived cmc article

Patent metadata

Field	Value
Publication number	US-2016243722-A1
Application number	US-201415026094-A
Country	US
Kind code	A1
Filing date	Sep 29, 2014
Priority date	Oct 7, 2013
Publication date	Aug 25, 2016
Grant date	—

Abstract

A disclosed method of forming a ceramic article includes forming a pre-ceramic polymer article within a mold tool, and performing a first pyrolizing step on the initial pre-ceramic polymer article to form a ceramic article. The method further includes performing at least one pre-heat treatment polymer infiltration and pyrolizing (PIP) cycle on the ceramic article and an initial heat treatment cycle of the ceramic article after the at least one pre-heat treatment PIP cycle. Subsequent PIP cycles and heat treatment cycles are performed in combination to form a ceramic article including a desired density.

First claim

What is claimed is:

1 . A method of forming a ceramic article comprising:
forming a pre-ceramic polymer article within a mold tool; performing a first pyrolizing step on the pre-ceramic polymer article to form a ceramic article; performing at least one pre-heat treatment polymer infiltration and pyrolizing (PIP) cycle on the ceramic article; performing an initial heat treatment cycle of the ceramic article after the at least one pre-heat treatment PIP cycle; performing at least one post-heat treatment PIP cycle after the at least one initial heat treatment process; and performing at least one heat treatment cycle after the at least one post-heat treatment PIP cycle.

2 . The method as recited in claim 1 , wherein the at least one pre-heat treatment PIP cycle on the ceramic article comprises at least two (2) PIP cycles.

3 . The method as recited in claim 1 , wherein the at least one pre-heat treatment PIP cycle on the ceramic article comprises at least six (6) PIP cycles.

4 . The method as recited in claim 1 , wherein the at least one post-heat treatment PIP cycle comprises at least two (2) PIP cycles.

5 . The method as recited in claim 1 , including performing the at least one heat treatment cycle after at least one (1) post-heat treatment PIP cycles.

6 . The method as recited in claim 5 , including repeating both the post heat treatment PIP cycle after one heat treatment cycle for between two (2) and eight (8) iterations.

7 . The method as recited in claim 5 , including performing the post heat treatment PIP cycle two (2) times after a one heat treatment cycle for between two (2) and eight (8) iterations.

8 . The method as recited in claim 1 , wherein the heat treatment cycle comprises exposing the ceramic article to a temperature between about 1200° C. and 1600° C.

9 . The method as recited in claim 1 , wherein the PIP cycle comprises heating the ceramic article to temperature between about 900° C. and 1100° C. in an inert environment.

10 . A method of forming a ceramic article comprising;
forming a pre-ceramic polymer article within a mold tool; performing a first pyrolizing step on the pre-ceramic polymer article to form a ceramic article; performing at least one pre-heat treatment polymer infiltration and pyrolizing (PIP) cycle on the ceramic article; performing an initial heat treatment of the ceramic article after the at least one pre-heat treatment PIP cycle; and performing a densification step after the initial heat treatment including at least one PIP cycle followed by a heat treatment process.

11 . The method as recited in claim 10 , including repeating the densification step for at least two (2) iterations.

12 . The method as recited in claim 10 , including repeating the densification step for between two (2) and eight (8) iterations.

13 . The method as recited in claim 10 , wherein the at least one pre-heat treatment PIP cycle comprises between two (2) and eight (8) cycles.

14 . The method as recited in claim 10 , wherein the densification step comprises at least two (2) PIP cycles followed by the heat treatment process.

15 . The method as recited in claim 10 , wherein the heat treatment cycle comprises exposing the ceramic article to a temperature between about 1200° C. and 1600° C.

16 . The method as recited in claim 10 , wherein the PIP cycle comprises heating the ceramic article to a temperature between about 900° C. and 1100° C. in an inert environment.

Assignees

• United Technologies Corp

Inventors

• Amini Shahram
• Schmidt Wayde R
• Kashyap Tania Bhatia
• Hermann Mark A
• Sheedy Paul
• Limarga Andi M
• Mccaffrey Michael G

Classifications

• B28B1/52

  specially adapted for producing articles from mixtures containing fibres, {e.g. asbestos cement}(by wrapping on to mandrels B28B1/42) · CPC title

• B28B1/24 Primary

  by injection moulding {(injection moulding of ceramic slips B28B1/265; of tubular articles B28B21/38)} · CPC title

• C04B2235/616

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

• C04B35/532

  containing a carbonisable binder · CPC title

• C04B35/524

  obtained from polymer precursors, e.g. glass-like carbon material · CPC title