Abstract: A method for producing silicon carbide directly from comminuted coal and a silicon precursor is described. The process includes coating comminuted coal with a silicon precursor and heating the silicon precursor coated comminuted coal to initially form polymerized preceramic silicon-carbon foam and then further heating to form silicon carbide foam.

Abstract: A method for producing a siliconized carbon foam with regions of silicon carbide directly from comminuted coal and particulate silicone resin precursor is described. The process includes blending a comminuted coal and particulate silicone resin and heating the blended mixture to form a siliconized carbon foam and then further heating to form regions of silicon carbide.

Abstract: Disclosed are methods for producing carbon foam in which using the vitrinite reflectance values of coals are used to form a blended coal precursor having a targeted vitrinite reflectance value. The targeted vitrinite reflectance value can be used to create similar carbon foam products from one production batch to the next.

Abstract: A method for producing a siliconized carbon foam with regions of silicon carbide directly from comminuted coal and particulate silicone resin precursor is described. The process includes blending a comminuted coal and particulate silicone resin and heating the blended mixture to form a siliconized carbon foam and then further heating to form regions of silicon carbide.

Abstract: A method for producing silicon carbide directly from comminuted coal and a silicon precursor is described. The process includes coating comminuted coal with a silicon precursor and heating the silicon precursor coated comminuted coal to initially form polymerized preceramic silicon-carbon foam and then further heating to form silicon carbide foam.

Abstract: Producing silicon carbide carbon foam is described. The process includes filling the pores of a carbon foam with a polysiloxane resin and heating the impregnated carbon foam to high temperatures to convert the silicon in the polysiloxane resin to silicon carbon within the carbon foam.

Abstract: A porous metal and carbon composite lightning strike protection system is described that utilizes flexible metallic material and porous carbon. The carbon-based lightning strike protection system may be produced in the form of a panel that may be applied over the surface of an object to be protected or may be created directly over the surface of the object. The carbon-based lightning strike protection system is readily adaptable to high temperature applications.

Abstract: A carbon-based lightning strike protection system is described that utilizes flexible graphite and porous carbon. The carbon-based lightning strike protection system may be produced in the form of a panel that may be applied over the surface of an object to be protected or may be created directly over the surface of the object. The carbon-based lightning strike protection system is readily adaptable to high temperature applications.

Abstract: A segmented composite exhaust flue which may be used to shield an area or object from convective, conductive, or radiated heat transfer from hot exhaust combustion gases is described. In certain embodiments, the composite exhaust flue may be used to protect structures from hot exhaust gases and particles such as those produced by cars, trucks, ships, boats, jets, rockets, as well as other vehicles with internal combustion engines, turbines, or rocket motors. In some embodiments, a composite exhaust flue may include an attachment frame removeably holding a plurality of ceramic composite panels where the ceramic composite panels have a ceramic fiber reinforced ceramic composite high temperature face sheet positioned over an insulating layer.

Abstract: A high density carbon material produced from coal is described. The carbon material may have a density ranging from about 1.0 g/cc to about 1.6 g/cc and may have a crush strength of up to about 20,000 psi. The high density carbon material is produced by slowly heating comminuted swelling bituminous coal particles under pressures of 400 psi to about 500 psi to a first temperature at about the initial plastic temperature of the coal. The material is held at this temperature for a period of time sufficient to provide for a uniform temperature throughout the coal. The material is then heated to a second temperature for a period of time sufficient to provide for the coal achieving an essentially uniform temperature. The resulting product is a three-dimensional, self-supporting carbon that has a substantially continuous carbon matrix defining grain boundaries within the carbon matrix.