Abstract: A method for forming a ceramic sandwich-structured composite component includes applying one or more ceramic matrix composite (CMC) plies to a surface of a tool, and positioning a ceramic foam precursor with respect to the tool such that the ceramic foam precursor and the one or more CMC plies is disposed in a sealed interior cavity of the tool. The ceramic foam precursor and the one or more CMC plies are cured within the sealed interior cavity to form a green preform such that the ceramic foam precursor expands within the sealed interior cavity to apply a pressure to the one or more CMC plies to consolidate the one or more CMC plies. The expanded ceramic foam precursor forms a ceramic core of the green preform bonded to the one or more CMC plies. The green preform is removed from the tool and sintered to ceramify the green preform.

Abstract: A method for forming a ceramic sandwich-structured composite component includes applying one or more ceramic matrix composite (CMC) plies to a surface of a tool, and positioning a ceramic foam precursor with respect to the tool such that the ceramic foam precursor and the one or more CMC plies is disposed in a sealed interior cavity of the tool. The ceramic foam precursor and the one or more CMC plies are cured within the sealed interior cavity to form a green preform such that the ceramic foam precursor expands within the sealed interior cavity to apply a pressure to the one or more CMC plies to consolidate the one or more CMC plies. The expanded ceramic foam precursor forms a ceramic core of the green preform bonded to the one or more CMC plies. The green preform is removed from the tool and sintered to ceramify the green preform.

Abstract: Systems and methods for thermally processing composite components are provided. In one exemplary aspect, a system includes a thermal system, a mover device, and a control system. The system also includes a plurality of vessels in which one or more components may be placed. The vessels are similarly shaped and configured. A vessel containing the one or more components therein may be mounted into a chamber defined by the thermal system during thermal processing. The thermal system and vessels include features that allow components to be thermally processed, e.g., compacted, burnt-out, and densified via a melt-infiltration process, a polymer impregnation and pyrolyzing process, or a chemical vapor infiltration process. utilizing the same thermal system and common vessel design. The control system may control the thermal system and mover device to automate thermal processing of the composite components.

Abstract: Systems and methods for thermally processing composite components are provided. In one exemplary aspect, a system includes a thermal system, a mover device, and a control system. The system also includes a plurality of vessels in which one or more components may be placed. The vessels are similarly shaped and configured. A vessel containing the one or more components therein may be mounted into a chamber defined by the thermal system during thermal processing. The thermal system and vessels include features that allow components to be thermally processed, e.g., compacted, burnt-out, and densified via a melt-infiltration process, a polymer impregnation and pyrolyzing process, or a chemical vapor infiltration process. utilizing the same thermal system and common vessel design. The control system may control the thermal system and mover device to automate thermal processing of the composite components.

Abstract: Systems and methods for thermally processing composite components are provided. In one exemplary aspect, a system includes a thermal system, a mover device, and a control system. The system also includes a plurality of vessels in which one or more components may be placed. The vessels are similarly shaped and configured. A vessel containing the one or more components therein may be mounted into a chamber defined by the thermal system during thermal processing. The thermal system and vessels include features that allow components to be thermally processed, e.g., compacted, burnt-out, and densified via a melt-infiltration process, a polymer impregnation and pyrolyzing process, or a chemical vapor infiltration process. utilizing the same thermal system and common vessel design. The control system may control the thermal system and mover device to automate thermal processing of the composite components.

Abstract: Systems and methods for thermally processing composite components are provided. In one exemplary aspect, a system includes a thermal system, a mover device, and a control system. The system also includes a plurality of vessels in which one or more components may be placed. The vessels are similarly shaped and configured. A vessel containing the one or more components therein may be mounted into a chamber defined by the thermal system during thermal processing. The thermal system and vessels include features that allow components to be thermally processed, e.g., compacted, burnt-out, and densified via a melt-infiltration process, a polymer impregnation and pyrolyzing process, or a chemical vapor infiltration process. utilizing the same thermal system and common vessel design. The control system may control the thermal system and mover device to automate thermal processing of the composite components.