Abstract: A method for forming temporary protective coatings and bondable surfaces is disclosed. In the method, a soluble layer is disposed on a material surface, such as the interior surfaces of cell walls of a web material. The soluble material is then removed or leached from the web material to form and expose a roughly textured, bondable surface for bonding with another material, such as AVCOAT insulation. Use of the soluble layer, therefore, enhances the bondability of any surface that requires good adhesion, such as where the surface is difficult to reach for conventional surface preparation techniques.

Abstract: A method for forming temporary protective coatings and bondable surfaces is disclosed. In the method, a soluble layer is disposed on a material surface, such as the interior surfaces of cell walls of a web material. The soluble material is then removed or leached from the web material to form and expose a roughly textured, bondable surface for bonding with another material, such as AVCOAT insulation. Use of the soluble layer, therefore, enhances the bondability of any surface that requires good adhesion, such as where the surface is difficult to reach for conventional surface preparation techniques.

Abstract: Formation of a filled honeycomb structure by interleaving layers of material and pre-formed pins made of a desired filler material is disclosed. In one embodiment, the material layers may be pre-impregnated and the pre-formed pins may be made of a foam, insulating material. The fabric layers and the pre-formed elongated foam members are assembled in an interleaved manner to form a raw assembly, and heat is applied to activate the resin and cure the raw assembly. The technique further involves allowing the raw assembly to cool to form a unitary, integral honeycomb structure.

Abstract: An improved clutch or brake device in which at least two members are mounted for relative rotation and engagement, the members having friction material rotatable therewith, and the friction material of the members having surfaces confronting each other, characterized in that the friction material has a solid density of greater than 30% and includes an open lattice of carbon ligaments forming a network of three dimensionally interconnected cells; and a pyrolytic carbon coating on the open lattice of carbon ligaments.

Abstract: A composite structure is formed by depositing a one or more coatings on an open-cell foam skeleton to form a higher-density composite foam. In accordance with one aspect of the invention, the composite foam can be a carbon/carbon composite formed by a rapid densification process. The composite structure is suitable for use, for example, as a friction material employed in clutch and brake devices.

Abstract: A composite structure is formed by depositing a one or more coatings on an open-cell foam skeleton to form a higher-density composite foam. In accordance with one aspect of the invention, the composite foam can be at carbon carbon composite formed by a rapid densification process. The form composite structure is suitable for use, for example, as a friction material employed in clutch and brake devices.

Abstract: A composite structure is formed by depositing a one or more coatings on an open-cell foam skeleton to form a higher-density composite foam. In accordance with one aspect of the invention, the composite foam can be a carbon/carbon composite formed by a rapid densification process. The composite structure is suitable for use, for example, as a friction material employed in clutch and brake devices.

Abstract: The present invention relates to carbon-matrix composites, such as carbon—carbon composites, and a method for forming them by forming a fabric of fusible and infusible fibers which can be processed and carbonized to form a composite. The methods disclosed herein permit preparation of composites which are particularly thin, uniform, and highly pure. The invention also relates to preprocessed fabrics and precarbonized composites, such as those comprising carbon or oxidized polyacrylonitrile fibers and fusible polyacrylonitrile fibers.

Abstract: The present invention relates to carbon-matrix composites, such as carbon-carbon composites, and a method for forming them by forming a fabric of fusible and infusible fibers which can be processed and carbonized to form a composite. The methods disclosed herein permit preparation of composites which are particularly thin, uniform, and highly pure. The invention also relates to preprocessed fabrics and precarbonized composites, such as those comprising carbon or oxidized polyacrylonitrile fibers and fusible polyacrylonitrile fibers.

Abstract: The invention relates to a surface treatment for silicon carbide filaments. A carbon-rich silicon carbide layer or coating is formed over the silicon carbide surface. The ratio of silicon to carbon in the carbon-rich silicon carbide layer varies from 1 (stoichiometric) at the silicon carbide filament interface to about 0.43 (70% carbon, 30% silicon) at the exterior surface of the carbon-rich layer. A preferred method of making the carbon-rich silicon carbide layer is also presented.

Abstract: A high strength silicon carbide monofilament which has a core and a stoichiometric bulk layer of silicon carbide deposited on the core having an exterior surface and a core bulk layer interface, the bulk layer having an average grain size of less than 200 nanometers which size varies continuously across the cross section of the bulk layer, the variation comprising a first average grain size at the interface which increases to a maximum average grain size intermediate the interface and the exterior surface and then decreases to the minimum at the exterior surface. In an alternate embodiment a surface layer is deposited on the bulk layer of silicon carbide. A preferred method of making the silicon carbide monofilament is also presented.

Abstract: A novel composition is described comprising an admixture of an unsaturated polyimide prepolymer essentially free of terminal amine groups and an epoxy resin having a homopolymerization temperature that is greater than the temperature at which the polyimide polymerizes. These compositions maintain the superior glass transition temperatures and moisture resistance of the polyimide while picking up the desirable handling properties of the epoxy. These compositions have excellent high temperature and moisture resistant properties and excellent storage stability. For instance, carbon composites made with these materials have exhibited 60% shear property retention at 450.degree. F. after being boiled in water for one week. Also described are prepregs comprising the novel composition, methods for curing the novel composition to obtain the superior properties, and articles of manufacture comprising the novel composition.

Abstract: Lightweight filament reinforced composite metal matrix structures is provided. The preferred process for producing tubing comprises wrapping alternate layers of metal and filament material to be molded around a mandrel. The mandrel is removed and in its place a test tube-shaped hollow glass cylinder is inserted. The wrapped cylinder is next placed in a cylindrical shaped mold and the entire assembly placed in an oven which is capable of heating the unit to the liquidus temperature of the metal matrix. The glass, which is of a type which softens at about the melting point of the matrix material, is pressurized to a medium high pressure. Under the influence of this pressure, the glass expands, forcing the composite metal matrix against the interior surface of the mold. The consolidated tubing is then cooled to a completely solidified state and removed from the mold.