Abstract: A method of fabricating a coating includes providing a ceramic matrix composite that includes SiC fibers disposed in a SiC matrix, depositing a base slurry on the ceramic matrix composite, wherein the base slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, and barium-magnesium-aluminosilicate in a first carrier fluid, drying the deposited base slurry to produce a base green layer, depositing a transition slurry on the base green layer, wherein the transition slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, at least one of zirconium carbide, zirconium nitride, or zirconium oxide, and barium-magnesium-aluminosilicate in a second carrier fluid, drying the deposited transition slurry to produce a transition green layer, and forming a consolidated coating on the ceramic matrix composite by heating the base green layer and the at least one transition green layer to cause chemical reactions that conv

Abstract: A method of fabricating a coating includes providing a ceramic matrix composite that includes SiC fibers disposed in a SiC matrix, depositing a base slurry on the ceramic matrix composite, wherein the base slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, and barium-magnesium-aluminosilicate in a first carrier fluid, drying the deposited base slurry to produce a base green layer, depositing a transition slurry on the base green layer, wherein the transition slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, at least one of zirconium carbide, zirconium nitride, or zirconium oxide, and barium-magnesium-aluminosilicate in a second carrier fluid, drying the deposited transition slurry to produce a transition green layer, and forming a consolidated coating on the ceramic matrix composite by heating the base green layer and the at least one transition green layer to cause chemical reactions that conv

Abstract: A method of preparing a woven fabric material for use in a ceramic matrix composite includes passing a desized woven fabric tape having a first inter-filament spacing through a dispersal module configured to transform the desized woven fabric tape into a dispersed woven fabric tape having a second inter-filament spacing greater than the first inter-filament spacing. The dispersal module includes a first charging element with a charged surface and disposed to apply an electric charge to the desized woven fabric tape. The method further includes applying a polymer binder to the dispersed woven fabric tape to create a stabilized woven fabric tape having the second inter-filament spacing.

Abstract: A method for manufacturing ceramic matrix composites (CMC) and CMCs made by the method are disclosed. The method can be a manual process or an automated process, such as using a robotic system, that is used for controlled delivery of ceramic particles in a CMC fabric. The method includes identifying voids present between adjacent tows of the CMC fabric and dispensing ceramic particles into the voids. Applying the ceramic particles in the center of the voids reduces the size and volume fraction of the voids/defects, improving the homogeneity of surface texture of the preform, homogeneity of microstructure, and part model shape conformity. The method for manufacturing CMCs creates CMCs having a homogenous distribution of small pores after matrix formation that improves the interlaminar mechanical and thermal properties of the CMCs.

Abstract: A method of manufacturing ceramic matrix composites includes producing chemical vapor deposition functionalized ceramic particles before injecting the functionalized ceramic particles into the CMC fabric. The functionalized ceramic particles are mixed with a binder solution and then dispensed into voids present between adjacent tows of the CMC fabric. Injecting the particles in the center of the voids reduces the size and volume fraction of the voids/defects, improving the homogeneity of surface texture, homogeneity of microstructure, and part model shape conformity.

Abstract: A method of preparing a woven fabric material for use in a ceramic matrix composite includes passing a desized woven fabric tape having a first inter-filament spacing through a dispersal module configured to transform the desized woven fabric tape into a dispersed woven fabric tape having a second inter-filament spacing greater than the first inter-filament spacing. The dispersal module includes a first charging element with a charged surface and disposed to apply an electric charge to the desized woven fabric tape. The method further includes applying a polymer binder to the dispersed woven fabric tape to create a stabilized woven fabric tape having the second inter-filament spacing.

Abstract: A method of fabricating a coating includes providing a ceramic matrix composite that includes SiC fibers disposed in a SiC matrix, depositing a base slurry on the ceramic matrix composite, wherein the base slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, and barium-magnesium-aluminosilicate in a first carrier fluid, drying the deposited base slurry to produce a base green layer, depositing a transition slurry on the base green layer, wherein the transition slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, at least one of zirconium carbide, zirconium nitride, or zirconium oxide, and barium-magnesium-aluminosilicate in a second carrier fluid, drying the deposited transition slurry to produce a transition green layer, and forming a consolidated coating on the ceramic matrix composite by heating the base green layer and the at least one transition green layer to cause chemical reactions that conv