Abstract: Methods are disclosed herein to fabricate high-strength ceramic matrix composite (CMC) structures by combining, in one example, pre-impregnated (prepreg) material with a pre-ceramic polymer. The prepreg is processed to a first density, and the densification is completed with repeated polymer infiltration and pyrolysis (PIP) cycles of the pre-ceramic polymer to fabricate a CMC structure. Advantageously, the present invention allows for fabrication of ceramic matrix composites more efficiently and to a larger scale than previously available.

Abstract: A method for use in manufacturing a ceramic matrix composite article includes assembling a ceramic fiber sheet between a tool and a die, where the tool is conformable to the shape of the die and the melting point of the die is greater than the melting point of the tool. The assembly is then heated to soften the tool. At least one of the tool, the die or a separate inflatable member is then pressurized to conform the tool and the ceramic fiber sheet to the die. Next, the assembly is cooled and the pressure is vented before removal of the tool and ceramic fiber sheet from the die. A preceramic resin with a catalyst is then applied to the ceramic fiber sheet and cured at a curing temperature that is below the melting point of the tool, to form a preform. The tool is then removed from the preform.

Abstract: A method for use in the manufacturing of a composite article includes wrapping a first fiber sheet around a mandrel that includes a plurality of needles that extends therefrom such that the plurality of needles pass through the first fiber sheet. The first fiber sheet includes a plurality of fibers and a plurality of interstitial areas and all of the plurality of fibers in the first sheet is intact. A second fiber sheet is wrapped around the mandrel such that the plurality of needles passes through the second fiber sheet. The second fiber sheet includes a plurality of fibers and a plurality of interstitial areas and all of the plurality of fibers in the second sheet is intact.

Abstract: A method for use in manufacturing a ceramic matrix composite article includes assembling a ceramic fiber sheet between a tool and a die, where the tool is conformable to the shape of the die and the melting point of the die is greater than the melting point of the tool. The assembly is then heated to soften the tool. At least one of the tool, the die or a separate inflatable member is then pressurized to conform the tool and the ceramic fiber sheet to the die. Next, the assembly is cooled and the pressure is vented before removal of the tool and ceramic fiber sheet from the die. A preceramic resin with a catalyst is then applied to the ceramic fiber sheet and cured at a curing temperature that is below the melting point of the tool, to form a preform. The tool is then removed from the preform.

Abstract: Methods are disclosed herein to fabricate high-strength ceramic matrix composite (CMC) structures by combining, in one example, pre-impregnated (prepreg) material with a pre-ceramic polymer. The prepreg is processed to a first density, and the densification is completed with repeated polymer infiltration and pyrolysis (PIP) cycles of the pre-ceramic polymer to fabricate a CMC structure. Advantageously, the present invention allows for fabrication of ceramic matrix composites more efficiently and to a larger scale than previously available.