Abstract: Systems and methods for weaving helical carbon fabrics with minimum fiber crimp are provided herein. In various embodiments, small denier natural or synthetic yarns are used in the warp direction to interlace the carbon fiber wefts with minimum deformation. Specific weave designs are used in combination with the small denier yarn to maintain the primary carbon fiber weft and warp un-crimped.

Abstract: The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp during the transferring the carbon short fibers. The base layer may comprise an annular shape.

Abstract: A method of treating a carbon structure is provided. The method may include the step of infiltrating the carbon structure with a ceramic preparation comprising yttrium oxides and zirconium oxides. The carbon structure may be densified by chemical vapor infiltration (CVI) and heat treated to form yttrium oxycarbides and/or carbides and zirconium oxycarbides and/or carbides. Heat treating the carbon structure may comprise a temperature ranging from 1000° C. to 1600° C.

Abstract: The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp during the transferring the carbon short fibers. The base layer may comprise an annular shape.

Abstract: A preform manufacturing apparatus comprising a supply of fiber strip, a moveable positive fiber strip delivery mechanism coupled between a desired lay down location and the supply of fiber strip to positively deliver and orient the supply of fiber strip to the desired lay down location, and an electronic unwinder coupled to the supply of fiber strip is described herein. The electronic unwinder is configured to interact with the moveable positive fiber strip delivery mechanism.

Abstract: The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp during the transferring the carbon short fibers. The base layer may comprise an annular shape.

Abstract: A loom system for making a fibrous preform may comprise a base, a bedplate coupled to the base, wherein the bedplate is configured to rotate about an axis of rotation, and an air entangling module coupled to the base. The air entangling module may comprise an air entangling head coupled to an outer support and an inner support, wherein the air entangling head is configured to apply a jet of air toward the bedplate at an entangling zone. The air entangling head may have freedom of motion along the outer support and the inner support, and may be configured to rest on top of a fibrous layer.

Abstract: A method of treating a carbon structure is provided. The method may include the step of infiltrating the carbon structure with a ceramic preparation comprising yttrium oxides and zirconium oxides. The carbon structure may be densified by chemical vapor infiltration (CVI) and heat treated to form yttrium oxycarbides and/or carbides and zirconium oxycarbides and/or carbides. Heat treating the carbon structure may comprise a temperature ranging from 1000° C. to 1600° C.

Abstract: Processes for making carbon/carbon parts are provided. The process involves compression, carbonization and densification steps. Pressure may be applied to a fibrous preform prior to the carbonization step at a temperature less than an exothermic temperature to increase the fiber volume ratio of the fibrous preform. The densification steps may include filling the voids of the fibrous preform with a carbon matrix.

Abstract: A method of treating a carbon structure is provided. The method may include infiltrating the carbon structure with a silicon compound preparation, heat treating the carbon structure to form a plurality of silicon carbide whiskers in the carbon structure, and/or densifying the carbon structure.

Abstract: A method of treating a carbon structure is provided. The method may include the step of infiltrating the carbon structure with a ceramic preparation comprising yttrium oxides and zirconium oxides. The carbon structure may be densified by chemical vapor infiltration (CVI) and heat treated to form yttrium oxycarbides and/or carbides and zirconium oxycarbides and/or carbides. Heat treating the carbon structure may comprise a temperature ranging from 1000° C. to 1600° C.

Abstract: A loom system for making a fibrous preform may comprise a base, a bedplate coupled to the base, wherein the bedplate is configured to rotate about an axis of rotation, and an air entangling module coupled to the base. The air entangling module may comprise an air entangling head coupled to an outer support and an inner support, wherein the air entangling head is configured to apply a jet of air toward the bedplate at an entangling zone. The air entangling head may have freedom of motion along the outer support and the inner support, and may be configured to rest on top of a fibrous layer.

Abstract: A system and method for ceramic doping of carbon fiber materials is disclosed. A carbon fiber preform may be made of carbonized oxidized PAN fibers and may be placed in contact with a nanoparticle suspension having nanoparticles and a dispersion medium. The nanoparticles may impregnate the carbon fiber preform, causing it to become a doped carbon fiber preform. The doped carbon fiber preform may be densified. The doped carbon fiber preform may be densified by conventional CVI processing techniques. The doped carbon fiber preform may be densified by thermal gradient CVI.

Abstract: The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp during the transferring the carbon short fibers. The base layer may comprise an annular shape.

Abstract: A system and method for ceramic doping of carbon fiber materials is disclosed. A carbon fiber preform may be made of carbonized oxidized PAN fibers and may be placed in contact with a nanoparticle suspension having nanoparticles and a dispersion medium. The nanoparticles may impregnate the carbon fiber preform, causing it to become a doped carbon fiber preform. The doped carbon fiber preform may be densified. The doped carbon fiber preform may be densified by conventional CVI processing techniques. The doped carbon fiber preform may be densified by thermal gradient CVI.

Abstract: A method of treating a carbon structure is provided. The method may include infiltrating the carbon structure with a silicon compound preparation, heat treating the carbon structure to form a plurality of silicon carbide whiskers in the carbon structure, and/or densifying the carbon structure.

Abstract: A transport of carbon fiber bundles, in as fabricated carbon fiber tow form, with in-line manipulation of the fiber bundles (spreading or spreading and volumization with manipulators) during fiber bundle transport is described herein. A method including positively transporting and placing a fiber bundle via a moveable fiber bundle delivery mechanism interposed between a fiber bundle supply and a fiber bundle delivery location, manipulating at least one of a fiber volume and an areal weight of the fiber bundle via an air jet device coupled between the fiber bundle delivery location and the fiber bundle supply, and controlling delivery of the fiber bundle tension from the fiber supply through an electronic unwinder is also described.

Abstract: A method of treating a carbon-carbon structure is provided. The method includes the step of infiltrating the carbon-carbon structure with a ceramic preparation comprising an oxide compound and at least one of a boron compound or an oxide-boron compound to obtain a uniform distribution of the ceramic preparation within a porosity of the carbon-carbon structure. The carbon-carbon structure may be densified by chemical vapor infiltration (CVI) and heat treated to form borides. Heat treating the carbon-carbon may comprise a temperature ranging from 1000° C. to 1900° C.

Abstract: A preform manufacturing apparatus comprising a supply of fiber strip, a moveable positive fiber strip delivery mechanism coupled between a desired lay down location and the supply of fiber strip to positively deliver and orient the supply of fiber strip to the desired lay down location, and an electronic unwinder coupled to the supply of fiber strip is described herein. The electronic unwinder is configured to interact with the moveable positive fiber strip delivery mechanism.

Abstract: A method of treating a carbon structure is provided. The method may include the step of infiltrating the carbon structure with a ceramic preparation comprising yttrium oxides and zirconium oxides. The carbon structure may be densified by chemical vapor infiltration (CVI) and heat treated to form yttrium oxycarbides and/or carbides and zirconium oxycarbides and/or carbides. Heat treating the carbon structure may comprise a temperature ranging from 1000° C. to 1600° C.