Abstract: A method of producing a melt infiltrated ceramic matrix composite (CMC) article that includes the steps of: forming a ceramic fiber preform; optionally, rigidizing the ceramic fiber preform with a fiber interphase coating via a Chemical Vapor Infiltration (CVI) process, infiltrating a ceramic slurry into the porous body or preform, conducting one or more secondary operations, and finally, melt infiltrating the preform with molten silicon or a silicon alloy to form the CMC article. The infiltration of a ceramic slurry into a ceramic fiber preform to form a green body is performed along with the use of convection and/or conduction as heat transfer mechanisms, such that the ceramic slurry does not require the incorporation of a pre-gelation material in order for the slurry to remain within the green body during subsequent processing steps.

Abstract: A method of producing a CMC component that includes forming a preform having a plurality of ceramic fiber plies with each ply occupying a predetermined position; rigidizing the preform with a fiber interphase coating; inspecting the preform to determine which of the plies has partially or fully delaminated; reworking the delaminated plies in the preform; infiltrating a ceramic slurry into the preform to form a green body; optionally, conducting a secondary operation on the green body; and infiltrating the green body with a molten silicon or silicon alloy to form the CMC component. The step of reworking delaminated plies may also be applied to a green body formed after ceramic slurry infiltration into a rigidized fiber preform.

Abstract: A method of producing a CMC having a smooth surface includes forming a fiber preform; rigidizing the preform with an interphase coating; infiltrating a ceramic slurry into the preform to form a green body; conducting secondary operations on the green body; applying a slurry-based layer onto a portion of the green body; and infiltrating the green body with a molten silicon or silicon alloy, such that the CMC exhibits a smooth surface. The application of the slurry-based surface layer onto the green body includes placing the green body into a tool fixture having upper and lower components, such that a gap is present between the green body and at least one of the upper and lower components; and delivering a surface layer slurry into at least one gap, such that the surface layer slurry forms the slurry-based layer on at least a portion of the green body.