Abstract: A composition is for use with fabricating a ceramic composite stiffening member that defines a T-section. The stiffening member includes a web portion, at least one flange portion, a radius region disposed between the web portion and the at least one flange portion, and a skin member that is secured to the at least one flange portion and the radius region. The composition is a pliable mixture of refractory particles, plasticizers, silica-yielding polymers, and solvents that is applied along the radius region.

Abstract: The present invention is an integral composite structural (ICS) material comprising an open metal structure having at least one external side and internal surfaces defining a plurality of open shapes with a ceramic matrix composite bonded to at least one external side and the surfaces of at least a substantial portion of the plurality of open shapes and occupying at least a substantial portion of the plurality of open shapes. The open metal structure, independent of the ceramic matrix composite, has a total metal volume percent in the range of about 10% to about 90%, with no dimension of any open shape being greater than about ¾ inch. The ceramic matrix layer covers a substantial portion of at least one external side of the open metal structure.

Abstract: A composition is for use with fabricating a ceramic composite stiffening member that defines a T-section. The stiffening member includes a web portion, at least one flange portion, a radius region disposed between the web portion and the at least one flange portion, and a skin member that is secured to the at least one flange portion and the radius region. The composition is a pliable mixture of refractory particles, plasticizers, silica-yielding polymers, and solvents that is applied along the radius region.

Abstract: The present invention is an integral composite structural (ICS) material comprising an open metal structure having at least one external side and internal surfaces defining a plurality of open shapes with a ceramic matrix composite bonded to at least one external side and the surfaces of at least a substantial portion of the plurality of open shapes and occupying at least a substantial portion of the plurality of open shapes. The open metal structure, independent of the ceramic matrix composite, has a total metal volume percent in the range of about 10% to about 90%, with no dimension of any open shape being greater than about ¾ inch. The ceramic matrix layer covers a substantial portion of at least one external side of the open metal structure.

Abstract: Methods are provided for producing a ceramic matrix composite by slurry infiltration. The methods involve placing a desized ceramic cloth lay-up into a non-ceramic cloth bag, sealing the bag to form a bagged ceramic preform, infiltrating the bagged ceramic preform with a ceramic-containing slurry, and sintering the preform to convert the slurry to a ceramic while decomposing the non-ceramic bag. The methods of the present invention maximize slurry infiltration of the ceramic cloth tow bundle while minimizing damage to the ceramic cloth.

Abstract: A ceramic matrix composite (CMC) structure, and method of forming same, the structure having internal air flow channels and cooling holes created by the process of sewing or stitching a fugitive fiber or thread into plies of ceramic cloth, preferably prior to consolidation of the ceramic cloth with a CMC slurry, followed by heating to convert the slurry material to a hardened ceramic component part of a predetermined shape. Upon heating the infiltrated and consolidated ceramic cloth to about between 1100 and 2100 degrees Fahrenheit, such as by hot pressing the structure containing the fugitive fibers therein, the fugitive fibers disintegrate, leaving channels and cooling holes wherever the stitched fugitive fiber or thread was previously located. Thus, the channels and cooling holes flow between plies as well as across the surface of the top and bottom plies.