Abstract: A method of forming z-channels in a fibrous ceramic preform includes mounting the preform in a tooling assembly, the tooling assembly comprising a first fixture and a second fixture, heating the preform mounted in the tooling assembly to a temperature above a glass transition temperature of a polymer binder within the preform to induce a softened state of the polymer binder, inserting a plurality of needles sequentially through respective first holes in the first fixture, the preform, and respective corresponding second holes in the second fixture, and removing the plurality of needles leaving behind a corresponding plurality of z-channels in the preform.

Abstract: A method of spreading fibers of a tow including heat treating a fibrous preform having a plurality of tows and a resin mixture including an alcohol soluble binder, washing the fibrous preform with a solution of water and a water-soluble binder such that the solution occupies an intra-tow space of the plurality of tows, freezing the solution in the intra-tow space of the plurality of tows, and freeze-drying the fibrous preform. The method also includes making a CMC from the fibrous preform with spread tows.

Abstract: A dry prepreg of fibrous textile/thermoplastic with handling characteristics highly compatible with robotic handling and a method for making at least one dry prepreg and forming the at least one dry prepreg over a mold form. The method also includes using the at least one molded dry prepreg as at least one sub-laminate in a thermoforming process. The methods include CMC preforming processes which can be automated though the use of robotic handling devices.

Abstract: Woven fiber preforms are disclosed which have a base section and one or more leg sections positioned the base section, The base section and the leg sections together are a made of a single three-dimensional woven fiber structure comprising warp and weft fiber tows. The woven structure includes connecting weft tow sections that connect the base section to each of the leg sections. The connecting weft tow sections include through-the-thickness tow regions that pass from a leg section through the thickness (height) of the base section.

Abstract: A method of forming z-channels in a fibrous ceramic preform includes mounting the preform in a tooling assembly, the tooling assembly comprising a first fixture and a second fixture, heating the preform mounted in the tooling assembly to a temperature above a glass transition temperature of a polymer binder within the preform to induce a softened state of the polymer binder, inserting a plurality of needles sequentially through respective first holes in the first fixture, the preform, and respective corresponding second holes in the second fixture, and removing the plurality of needles leaving behind a corresponding plurality of z-channels in the preform.

Abstract: A method of fabricating a fibrous ceramic preform includes forming a plurality of coated ceramic tows by introducing a polymeric composition to each of a plurality of ceramic tows, and dispersing and stabilizing each of the plurality of ceramic tows such that a coating of a first polymer binder forms on individual filaments of respective ones of the plurality of ceramic tows, incorporating the plurality of coated ceramic tows into a ceramic fabric, applying a tackifier composition comprising a second polymer binder and a second solvent to the ceramic fabric, and incorporating the ceramic fabric into the preform. The first polymer binder is insoluble in the second solvent.

Abstract: A method of fabricating a fibrous ceramic preform includes impregnating a plurality of individual ceramic tows with a first polymer binder, incorporating the plurality of impregnated ceramic tows into a ceramic fabric, applying a solution comprising a second polymer binder and a second solvent to the ceramic fabric, and incorporating the ceramic fabric into the preform. The first polymer binder is insoluble in the second solvent.

Abstract: A method of forming a ceramic matrix composite includes preparing a plurality of fibrous ceramic plies by applying a binder solution loaded with ceramic particles to each of a first subset of plies, and applying the binder solution without ceramic particles to each of a second subset of plies. The method further includes arranging the plurality of plies to form a preform with a gradient along a thickness direction of the preform by stacking the first subset of plies to form a first zone of the preform, and stacking individual ones of the second subset of the plies on both sides of the first zone to form a second zone on each side of the first zone. Loading of the ceramic particles is higher in the first zone than in the second zones. The method further includes densifying the preform with a ceramic matrix.

Abstract: Thermoset resin compositions including a compound of formula (I) having a working life and/or a pot life of at least 1 hour are provided. Copolymers prepared from the thermoset resin compositions are further provided. Methods of preparing and polymerizing the thermoset resin compositions are further provided. Delivery devices for preparing thermoset resin compositions are further provided.