US20070054103A1 - Methods and apparatus for forming a composite protection layer - Google Patents
Methods and apparatus for forming a composite protection layer Download PDFInfo
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- US20070054103A1 US20070054103A1 US11/220,817 US22081705A US2007054103A1 US 20070054103 A1 US20070054103 A1 US 20070054103A1 US 22081705 A US22081705 A US 22081705A US 2007054103 A1 US2007054103 A1 US 2007054103A1
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
- C04B35/62844—Coating fibres
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
- C04B35/62844—Coating fibres
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
- C04B35/62894—Coating the powders or the macroscopic reinforcing agents with more than one coating layer
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/52—Constituents or additives characterised by their shapes
- C04B2235/5208—Fibers
- C04B2235/5216—Inorganic
- C04B2235/524—Non-oxidic, e.g. borides, carbides, silicides or nitrides
- C04B2235/5248—Carbon, e.g. graphite
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/614—Gas infiltration of green bodies or pre-forms
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
Definitions
- the present invention relates generally to ceramic composites, and, more particularly, to protecting composites from oxidation at high temperatures.
- Materials suitable for extended periods of exposure to high temperature and/or high stress environments are desired for a variety of applications.
- a plurality of such materials exist, for example, coated, ceramic composite materials have been used in these conditions with varying degrees of success.
- a composite material consists of two or more physically, and/or chemically, distinct constituents coupled together with an interface separating them.
- the constituents of such a composite do not dissolve or otherwise merge completely into each other.
- the composites act synergistically with each other.
- Composite materials have characteristics that are not normally exhibited and may be unattainable by any of the constituents in isolation. Examples of performance features that may be improved through the use of composites include enhanced material strength, toughness, and/or heat resistance.
- At least some known composite materials include a continuous phase, known as a matrix and a dispersed, non-continuous phase known as a reinforcement. The reinforcement generally is harder and stronger than the matrix.
- An example composite is a carbon-fiber reinforced silicon carbide matrix (C/SiC) ceramic composite typically used in applications that require high strength and heat resistance. Carbon fibers can retain their properties at high temperatures (for example, 1650 degrees C.). Carbon fibers, however, may be prone to oxidation in such high temperature environments.
- the combination of a SiC matrix having a greater stiffness and oxidation resistance, in conjunction with an interfacial coating and additional surface seal coating may provide protection for the carbon fibers.
- oxygen may infiltrate the ceramic composite matrix and react with the carbon fibers.
- the oxidation reaction weakens the carbon fibers and may subsequently weaken areas within the composite. Weakened areas can result in a loss of material and may eventually lead to a material failure.
- Barrier coatings such as a SiC matrix have proven moderately effective in retarding oxidation; however, oxidizing species may diffuse through the matrix coating to reach the carbon fiber.
- a method for reducing oxidation in ceramic composites includes depositing a first portion of a silicon carbide (SiC) matrix over at least a portion of an article using a first chemical vapor infiltration (CVI) process, depositing a silicon (Si)-doped boron nitride (BN) layer within at least a portion of the SiC matrix using a second CVI process, and depositing a second portion of the SiC matrix within at least a portion or in continuation of the first portion of the SiC matrix using a third CVI process.
- SiC silicon carbide
- CVI chemical vapor infiltration
- a method for fabricating a ceramic composite article includes fabricating a carbon fiber preform article with a plurality of pre-determined dimensions, depositing a layer of pyrolytic carbon on the carbon fiber over at least a portion of the carbon fiber preform article, depositing a first portion of a silicon carbide (SiC) matrix on at least a portion of the reinforcing pyrolytic carbon layer using a first chemical vapor infiltration (CVI) process, depositing a silicon (Si)-doped boron nitride (BN) layer within at least a portion of the SiC matrix using a second CVI process, and depositing a second portion of the SiC matrix within at least a portion of the first portion or in continuation of the SiC matrix using a third CVI process.
- SiC silicon carbide
- CVI chemical vapor infiltration
- an article comprising a ceramic composite protective layer.
- the layer includes a substrate comprised of a surface region, and a region of fiber bundles extending over at least a portion of the substrate infiltrated with a matrix material impregnated with an oxidizing agent.
- FIG. 1 is a flow chart of an exemplary method for forming a composite protective layer.
- FIG. 1 is a flow chart of an exemplary method 100 for forming a composite protective layer.
- a method step 110 of exemplary method 100 includes fabricating a carbon fiber preform article with a plurality of pre-determined dimensions that includes contours and thicknesses substantially similar to the dimensions of a finished article.
- the article is formed with a plurality of layers wherein the layers may have a plurality of pre-determined material densities that may be substantially homogeneous, or varied circumferentially and/or as a function of the contours of the article.
- the substrate primary interface for the subsequent layers is the surface of the article.
- a method step 120 of exemplary method 100 includes depositing a layer of pyrolytic carbon over the surface of the substrate.
- the layer of carbon is deposited with a thickness that may be uniform and homogenous, or with a plurality of thicknesses that may be varied circumferentially and/or as a function of the contours of the article.
- a method step 130 of exemplary method 100 includes depositing the first portion of a silicon carbide (SiC) matrix on the layer of pyrolytic carbon via a chemical vapor infiltration (CVI) process.
- CVI chemical vapor infiltration
- chemical reactants in vapor phase are introduced to the article and penetrate the porous substrate wherein a vapor phase reaction occurs.
- a ceramic matrix is formed by the infiltration of the vapors into the porous substrate.
- the SiC matrix is deposited at pre-determined carbon (C)-to-silicon (Si) ratios that may be homogeneous about the surface of the article or varied circumferentially and/or as a function of the contours of the article.
- the SiC matrix may be deposited while maintaining isothermal conditions (for example, normally, CVI for SiC is conducted at approximately 1000 degrees C.), or by varying the temperature of the preform wherein a pre-determined temperature gradient in the preform is maintained.
- the SiC matrix may be deposited while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate.
- the desired deposition rates and thicknesses are attained by controlling the temperature of the gaseous reactants, the pressure, the rate of flow of the reactants, the concentrations of the reactants, and the rate of removal of byproduct gases released by the reactions resulting from the interaction of the gaseous reactants with the substrate constituents.
- a method step 140 of exemplary method 100 includes interrupting the deposition of the SiC matrix and depositing a silicon (Si)-doped boron nitride (BN) layer within the SiC matrix using a CVI process.
- the CVI BN coating is deposited uniformly around each fiber and/or fiber bundle.
- the BN coating remains relatively stable at high temperatures.
- the BN coating reacts to form a B 2 O 3 (and/or Si—B—O) glass layer, which uniformly surrounds the fiber bundles, thereby, inhibiting further oxygen diffusion and facilitating the prevention of fiber and/or interface oxidation.
- BN can be obtained from a variety of compounds, for example, borazine (B 3 N 3 H 6 ) or a mixture of boron trichloride (BCI 3 ) and ammonia (NH 3 ).
- a method step 150 of exemplary method 100 includes continuing the CVI SiC matrix deposition once the BN layer is completely deposited.
- the CVI process for finishing the SiC matrix deposition may be identical to that used for the first deposition or the parameters may be adjusted to account for the prior discontinuation of the matrix deposition and the introduction of the BN layer in the matrix.
- the ceramic composite fabrication methods described herein facilitates reducing the oxidation of ceramic composite articles. More specifically, the glass layer described above prevents further diffusion of oxygen. As a result, the degradation of the ceramic composite articles and increased maintenance costs caused by article damage can be reduced or eliminated.
- Exemplary embodiments of C/SiC ceramic composites are described above in detail.
- the methods, apparatus and systems are not limited to the specific embodiments described herein nor to the specific C/SiC articles fabricated, but rather, the methods of fabricating ceramic composites may be utilized independently and separately from other methods, apparatus and systems described herein or to fabricate ceramic composites not described herein.
- other ceramic composites can also be assembled using the methods described herein.
Abstract
A method for reducing oxidation in ceramic composites is provided. The method includes depositing a first portion of a silicon carbide (SiC) matrix over at least a portion of an article using a first chemical vapor infiltration (CVI) process, depositing a silicon (Si)-doped boron nitride (BN) layer within at least a portion of the SiC matrix using a second CVI process, and depositing a second portion of the SiC matrix within at least a portion or continuation of the first portion of the SiC matrix using a third CVI process.
Description
- The present invention relates generally to ceramic composites, and, more particularly, to protecting composites from oxidation at high temperatures.
- Materials suitable for extended periods of exposure to high temperature and/or high stress environments are desired for a variety of applications. A plurality of such materials exist, for example, coated, ceramic composite materials have been used in these conditions with varying degrees of success.
- A composite material consists of two or more physically, and/or chemically, distinct constituents coupled together with an interface separating them. The constituents of such a composite do not dissolve or otherwise merge completely into each other. The composites, however, act synergistically with each other. Composite materials have characteristics that are not normally exhibited and may be unattainable by any of the constituents in isolation. Examples of performance features that may be improved through the use of composites include enhanced material strength, toughness, and/or heat resistance. At least some known composite materials include a continuous phase, known as a matrix and a dispersed, non-continuous phase known as a reinforcement. The reinforcement generally is harder and stronger than the matrix.
- An example composite is a carbon-fiber reinforced silicon carbide matrix (C/SiC) ceramic composite typically used in applications that require high strength and heat resistance. Carbon fibers can retain their properties at high temperatures (for example, 1650 degrees C.). Carbon fibers, however, may be prone to oxidation in such high temperature environments. The combination of a SiC matrix having a greater stiffness and oxidation resistance, in conjunction with an interfacial coating and additional surface seal coating may provide protection for the carbon fibers.
- In high temperature oxygen-rich environments, oxygen may infiltrate the ceramic composite matrix and react with the carbon fibers. The oxidation reaction weakens the carbon fibers and may subsequently weaken areas within the composite. Weakened areas can result in a loss of material and may eventually lead to a material failure. Barrier coatings such as a SiC matrix have proven moderately effective in retarding oxidation; however, oxidizing species may diffuse through the matrix coating to reach the carbon fiber.
- In one aspect, a method for reducing oxidation in ceramic composites is provided. The method includes depositing a first portion of a silicon carbide (SiC) matrix over at least a portion of an article using a first chemical vapor infiltration (CVI) process, depositing a silicon (Si)-doped boron nitride (BN) layer within at least a portion of the SiC matrix using a second CVI process, and depositing a second portion of the SiC matrix within at least a portion or in continuation of the first portion of the SiC matrix using a third CVI process.
- In another aspect, a method for fabricating a ceramic composite article is provided. The method includes fabricating a carbon fiber preform article with a plurality of pre-determined dimensions, depositing a layer of pyrolytic carbon on the carbon fiber over at least a portion of the carbon fiber preform article, depositing a first portion of a silicon carbide (SiC) matrix on at least a portion of the reinforcing pyrolytic carbon layer using a first chemical vapor infiltration (CVI) process, depositing a silicon (Si)-doped boron nitride (BN) layer within at least a portion of the SiC matrix using a second CVI process, and depositing a second portion of the SiC matrix within at least a portion of the first portion or in continuation of the SiC matrix using a third CVI process.
- In a further aspect, an article comprising a ceramic composite protective layer is provided. The layer includes a substrate comprised of a surface region, and a region of fiber bundles extending over at least a portion of the substrate infiltrated with a matrix material impregnated with an oxidizing agent.
-
FIG. 1 is a flow chart of an exemplary method for forming a composite protective layer. -
FIG. 1 is a flow chart of anexemplary method 100 for forming a composite protective layer. - A
method step 110 ofexemplary method 100 includes fabricating a carbon fiber preform article with a plurality of pre-determined dimensions that includes contours and thicknesses substantially similar to the dimensions of a finished article. The article is formed with a plurality of layers wherein the layers may have a plurality of pre-determined material densities that may be substantially homogeneous, or varied circumferentially and/or as a function of the contours of the article. The substrate primary interface for the subsequent layers is the surface of the article. - A
method step 120 ofexemplary method 100 includes depositing a layer of pyrolytic carbon over the surface of the substrate. The layer of carbon is deposited with a thickness that may be uniform and homogenous, or with a plurality of thicknesses that may be varied circumferentially and/or as a function of the contours of the article. - A
method step 130 ofexemplary method 100 includes depositing the first portion of a silicon carbide (SiC) matrix on the layer of pyrolytic carbon via a chemical vapor infiltration (CVI) process. In the CVI process, chemical reactants in vapor phase are introduced to the article and penetrate the porous substrate wherein a vapor phase reaction occurs. During this CVI process, a ceramic matrix is formed by the infiltration of the vapors into the porous substrate. - During the CVI process, the SiC matrix is deposited at pre-determined carbon (C)-to-silicon (Si) ratios that may be homogeneous about the surface of the article or varied circumferentially and/or as a function of the contours of the article. The SiC matrix may be deposited while maintaining isothermal conditions (for example, normally, CVI for SiC is conducted at approximately 1000 degrees C.), or by varying the temperature of the preform wherein a pre-determined temperature gradient in the preform is maintained. Also, the SiC matrix may be deposited while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate. The desired deposition rates and thicknesses are attained by controlling the temperature of the gaseous reactants, the pressure, the rate of flow of the reactants, the concentrations of the reactants, and the rate of removal of byproduct gases released by the reactions resulting from the interaction of the gaseous reactants with the substrate constituents.
- A
method step 140 ofexemplary method 100 includes interrupting the deposition of the SiC matrix and depositing a silicon (Si)-doped boron nitride (BN) layer within the SiC matrix using a CVI process. The CVI BN coating is deposited uniformly around each fiber and/or fiber bundle. The BN coating remains relatively stable at high temperatures. On contact with oxygen at high temperatures, the BN coating reacts to form a B2O3 (and/or Si—B—O) glass layer, which uniformly surrounds the fiber bundles, thereby, inhibiting further oxygen diffusion and facilitating the prevention of fiber and/or interface oxidation. BN can be obtained from a variety of compounds, for example, borazine (B3N3H6) or a mixture of boron trichloride (BCI3) and ammonia (NH3). - A
method step 150 ofexemplary method 100 includes continuing the CVI SiC matrix deposition once the BN layer is completely deposited. The CVI process for finishing the SiC matrix deposition may be identical to that used for the first deposition or the parameters may be adjusted to account for the prior discontinuation of the matrix deposition and the introduction of the BN layer in the matrix. - The ceramic composite fabrication methods described herein facilitates reducing the oxidation of ceramic composite articles. More specifically, the glass layer described above prevents further diffusion of oxygen. As a result, the degradation of the ceramic composite articles and increased maintenance costs caused by article damage can be reduced or eliminated.
- Although the methods described and/or illustrated herein are described and/or illustrated with respect to fabricating a ceramic composite article, and more specifically, a C/SiC ceramic composite, practice of the methods described and/or illustrated herein is not limited to C/SiC ceramic composite articles nor to composites reinforced with fibers other than carbon nor to ceramic composites generally. Rather, the methods described and/or illustrated herein are applicable to fabricating any article of any material.
- Exemplary embodiments of C/SiC ceramic composites are described above in detail. The methods, apparatus and systems are not limited to the specific embodiments described herein nor to the specific C/SiC articles fabricated, but rather, the methods of fabricating ceramic composites may be utilized independently and separately from other methods, apparatus and systems described herein or to fabricate ceramic composites not described herein. For example, other ceramic composites can also be assembled using the methods described herein.
- While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
Claims (20)
1. A method to reduce oxidation in ceramic composites, said method comprising:
depositing a first portion of a silicon carbide (SiC) matrix over at least a portion of an article using a first chemical vapor infiltration (CVI) process;
depositing a silicon (Si)-doped boron nitride (BN) layer within at least a portion of the SiC matrix using a second CVI process; and
depositing a second portion of the SiC matrix within at least a portion or in continuation of the first portion of the SiC matrix using a third CVI process.
2. A method to reduce oxidation in ceramic composites in accordance with claim 1 wherein said depositing a first portion of a SiC matrix over at least a portion of an article using a first CVI process comprises:
depositing the SiC matrix at pre-determined carbon (C)-to-silicon (Si) ratios that may be homogeneous about the surface of the article or varied circumferentially and/or as a function of the contours of the article;
depositing the SiC matrix while maintaining isothermal conditions, or varying the temperature of the article wherein a pre-determined temperature gradient in the article is maintained; and
depositing the SiC matrix while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate.
3. A method to reduce oxidation in ceramic composites in accordance with claim 2 wherein said depositing the SiC matrix at pre-determined C-to-Si ratios comprises controlling a plurality of first CVI process conditions which further comprises controlling a temperature of a plurality of gaseous reactants, a pressure, a rate of flow of the plurality of reactants, a plurality of concentrations of the plurality of reactants, and a rate of removal of a plurality of concentrations of a plurality of byproduct gases released by a plurality of reactions.
4. A method to reduce oxidation in ceramic composites in accordance with claim 1 , wherein said depositing a Si-doped BN layer within at least a portion of the SiC matrix using a second CVI process comprises:
interrupting said depositing a first portion of the SiC matrix;
depositing the Si-doped BN layer wherein substantially all of the carbon fiber bundles have a substantially uniform Si-doped BN layer coating;
controlling a plurality of second CVI process conditions which further comprises controlling a temperature of the preform, a temperature of a plurality of gaseous reactants, a pressure, a rate of flow of the plurality of reactants, a plurality of concentrations of the plurality of reactants, and a rate of removal of a plurality of concentrations of a plurality of byproduct gases released by a plurality of reactions wherein the second CVI process conditions may vary from the first CVI process conditions; and
depositing the Si-doped BN layer while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate.
5. A method to reduce oxidation in ceramic composites in accordance with claim 1 , wherein said depositing a second portion of the SiC matrix within at least a portion or in continuation of the first portion of the SiC matrix using a third CVI process comprises:
depositing the SiC matrix at pre-determined C-to-Si ratios that may be homogeneous about the surface of the article or varied circumferentially and/or as a function of the contours of the article;
depositing the SiC matrix while maintaining isothermal conditions, or varying the temperature of the article wherein a pre-determined temperature gradient in the article is maintained; and
depositing the SiC matrix while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate.
6. A method to reduce oxidation in ceramic composites in accordance with claim 5 wherein said depositing the SiC matrix at pre-determined C-to-Si ratios comprises controlling a plurality of third CVI process conditions which further comprises controlling a temperature of a plurality of gaseous reactants, a pressure, a rate of flow of the plurality of reactants, a plurality of concentrations of the plurality of reactants, and a rate of removal of a plurality of concentrations of a plurality of byproduct gases released by a plurality of reactions, wherein the third CVI process conditions may vary from the first and second CVI process conditions.
7. A method for fabricating a ceramic composite article, said method comprising:
fabricating a carbon fiber preform article with a plurality of pre-determined dimensions;
depositing a layer of pyrolytic carbon over at least a portion of the carbon fiber preform article;
depositing a first portion of a silicon carbide (SiC) matrix on at least a portion of the reinforcing layer using a first chemical vapor infiltration (CVI) process;
depositing a silicon (Si)-doped boron nitride (BN) layer within at least a portion of the SiC matrix using a second CVI process; and
depositing a second portion of the SiC matrix within at least a portion or in continuation of the first portion of the SiC matrix using a third CVI process.
8. A method for fabricating a ceramic composite article in accordance with claim 7 , wherein said fabricating a carbon fiber preform article with a plurality of pre-determined dimensions comprises:
pre-shaping the article to a set of pre-determined contours and thicknesses substantially similar to the dimensions of a finished article; and
forming the article with a plurality of layers wherein the layers may have a plurality of pre-determined material densities that may be substantially homogeneous, or varied circumferentially and/or as a function of the contours of the article.
9. A method for fabricating a ceramic composite article in accordance with claim 7 , wherein said forming a reinforcing layer of carbon fiber bundles over at least a portion of the carbon fiber preform article comprises:
modifying at least a portion of one surface of the article thereby developing a more porous, fibrous, and permeable substrate;
forming the layer of carbon fibers with a density and thickness that may be uniform and homogenous, or a plurality of densities and thicknesses that may be varied circumferentially and/or as a function of the contours of the article;
forming the layer of carbon fibers with a plurality of substantially uniform dimensions, or with a plurality of varied dimensions; and
forming the layer of carbon fibers with an orientation that may be uniform and homogenous, or a plurality of orientations that may be varied circumferentially and/or as a function of the contours of the article.
10. A method for fabricating a ceramic composite article in accordance with claim 7 , wherein said depositing a first portion of a silicon carbide (SiC) matrix on at least a portion of the reinforcing layer using a first chemical vapor infiltration (CVI) process comprises:
depositing the SiC matrix at pre-determined carbon (C)-to-Si ratios that may be homogeneous about the surface of the article or varied circumferentially and/or as a function of the contours of the article;
depositing the SiC matrix while maintaining isothermal conditions, or varying the temperature of the preform wherein a pre-determined temperature gradient in the preform is maintained; and
depositing the SiC matrix while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate.
11. A method for fabricating a ceramic composite article in accordance with claim 10 wherein said depositing the SiC matrix at pre-determined C-to-Si ratios comprises controlling a plurality of first CVI process conditions which further comprises controlling a temperature of a plurality of gaseous reactants, a pressure, a rate of flow of the plurality of reactants, a plurality of concentrations of the plurality of reactants, and a rate of removal of a plurality of concentrations of a plurality of byproduct gases released by a plurality of reactions.
12. A method for fabricating a ceramic composite article in accordance with claim 7 , wherein said depositing a Si-doped BN layer within at least a portion of the SiC matrix using a second CVI process comprises:
interrupting said depositing a first portion of the SiC matrix;
depositing the Si-doped BN layer wherein substantially all of the carbon fiber bundles have a substantially uniform Si-doped BN layer coating; and
controlling a plurality of second CVI process conditions which further comprises controlling a temperature of the preform, a temperature of a plurality of gaseous reactants, a pressure, a rate of flow of the plurality of reactants, a plurality of concentrations of the plurality of reactants, and a plurality of concentrations of a rate of removal of a plurality of byproduct gases released by a plurality of reactions wherein the second CVI process conditions may vary from the first CVI process conditions; and
depositing the Si-doped BN layer matrix while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate.
13. A method for fabricating a ceramic composite article in accordance with claim 7 , wherein said depositing a second portion of the SiC matrix within at least a portion of the first portion or in continuation of the SiC matrix using a third CVI process comprises:
depositing the SiC matrix at pre-determined C-to-Si ratios that may be homogeneous about the surface of the article or varied circumferentially and/or as a function of the contours of the article;
depositing the SiC matrix while maintaining isothermal conditions, or varying the temperature of the preform wherein a pre-determined temperature gradient in the preform is maintained; and
depositing the SiC matrix while the article is stationary or while the article is rotating about a pre-determined axis and at a pre-determined rate.
14. A method for fabricating a ceramic composite article in accordance with claim 13 wherein said depositing the SiC matrix at pre-determined C-to-Si ratios comprises controlling a plurality of third CVI process conditions which further comprises controlling a temperature of a plurality of gaseous reactants, a pressure, a rate of flow of the plurality of reactants, a plurality of concentrations of the plurality of reactants, and a rate of removal of a plurality of concentrations of a plurality of byproduct gases released by a plurality of reactions, wherein the third CVI process conditions may vary from the first and second CVI process conditions.
15. An article comprising a ceramic composite protective layer, said layer comprising:
a substrate comprised of a surface region; and
a region of fiber bundles extending over at least a portion of said substrate infiltrated with a matrix material impregnated with an oxidizing agent.
16. An article comprising a ceramic composite protective layer in accordance with claim 15 wherein said substrate further comprises a carbon fiber preform with pre-determined dimensions.
17. An article comprising a ceramic composite protective layer in accordance with claim 16 wherein said carbon fiber preform with pre-determined dimensions comprises:
an article pre-shaped to a set of pre-determined contours and thicknesses substantially similar to the dimensions of a finished article; and
a plurality of layers wherein said layers may have a plurality of pre-determined material densities that may be substantially homogeneous, or varied circumferentially and/or as a function of said contours of said article.
18. An article comprising a ceramic composite protective layer in accordance with claim 15 wherein said region of fiber bundles extending over at least a portion of said substrate infiltrated with a matrix material impregnated with an oxidizing agent comprises a layer of reinforcing carbon fiber bundles deposited over at least a portion of said preform.
19. An article comprising a ceramic composite protective layer in accordance with claim 15 wherein said region of fiber bundles extending over at least a portion of said substrate infiltrated with a matrix material impregnated with an oxidizing agent comprises a silicon carbide (SiC) matrix impregnated with a boron nitride (BN) oxidizing agent.
20. An article comprising a ceramic composite protective layer in accordance with claim 19 wherein said SiC matrix impregnated with a BN oxidizing agent may be deposited at pre-determined carbon (C)-to-silicon (Si) ratios that may be homogeneous about said surface region of the article or varied circumferentially and/or as a function of the contours of the article.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/220,817 US20070054103A1 (en) | 2005-09-07 | 2005-09-07 | Methods and apparatus for forming a composite protection layer |
EP20060254603 EP1762551A1 (en) | 2005-09-07 | 2006-09-04 | Method to reduce oxidation in ceramic composites, method for fabricating a ceramic composite article and an article comprising a ceramic composite protective layer |
CN2006101388518A CN1966467B (en) | 2005-09-07 | 2006-09-07 | Method and apparatus for fabricating a composite protective layer |
JP2006242822A JP2007070222A (en) | 2005-09-07 | 2006-09-07 | Method and apparatus for forming composite material protective layer |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US11/220,817 US20070054103A1 (en) | 2005-09-07 | 2005-09-07 | Methods and apparatus for forming a composite protection layer |
Publications (1)
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US20070054103A1 true US20070054103A1 (en) | 2007-03-08 |
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Family Applications (1)
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US11/220,817 Abandoned US20070054103A1 (en) | 2005-09-07 | 2005-09-07 | Methods and apparatus for forming a composite protection layer |
Country Status (4)
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US (1) | US20070054103A1 (en) |
EP (1) | EP1762551A1 (en) |
JP (1) | JP2007070222A (en) |
CN (1) | CN1966467B (en) |
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IT201800009953A1 (en) | 2018-10-31 | 2020-05-01 | Petroceramics Spa | Method and assembly of infiltration and rapid vapor deposition of porous components |
EP3647459A1 (en) | 2018-10-31 | 2020-05-06 | Petroceramics S.p.A. | Method and an assembly by chemical vapor infiltration of porous components |
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Also Published As
Publication number | Publication date |
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EP1762551A1 (en) | 2007-03-14 |
CN1966467B (en) | 2012-12-05 |
CN1966467A (en) | 2007-05-23 |
JP2007070222A (en) | 2007-03-22 |
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