Abstract: This disclosure provides an oxidation-resistant carbon-carbon composite that is molecularly inhibited with uniformly dispersed carbides. Nanoparticles of refractory metals and/or semi-metals suspended in a colloidal suspension infiltrate pores of a carbon-carbon composite during an initial pre-impregnation stage or carbon densification stage. The carbon-carbon composite is heated to form carbides that provide molecular level inhibition in both the interbundle and intrabundle matrix. The carbides are configured to form glass that serves as an oxidation barrier for the carbon-carbon composite. The carbon-carbon composite may be coated with external coatings that can include a converted silicon carbide, functionally graded material (FGM) ceramic coating, metallic coating, polymer-based coating, as-cured or low-temperature heat-treated sealant, or combinations thereof.

Abstract: This innovation provides for a revolutionary advancement in the area of very thick and very high thermal conductivity carbon-carbon (C—C) composites for both commercial and military. Novel, surface treated to achieve desired chemistry, exhibiting no agglomeration, carbon-based fillers are used enabling stable slurries up to 45 wt % solids to be used in the composite pre-pregging for 1-D and 2-D, 2-5 D and 3-D preforms infiltration. The need for carbonization is eliminated. No closed porosity C—C composites are produced. Up to 12? thick C—C composites with no density gradient and thermal conductivity in excess of 650 W/mK were fabricated via chemically induced graphitization.

Abstract: A carbon composite structure, for example, an automotive engine piston, is made by preparing a matrix including of a mixture of non crystalline carbon particulate soluble in an organic solvent and a binder that has a liquid phase. The non crystalline particulate also contains residual carbon hydrogen bonding. An uncured structure is formed by combining the matrix mixture, for example, carbon fibers such as graphite dispersed in the mixture and/or graphite cloth imbedded in the mixture. The uncured structure is cured by pyrolyzing it in an inert atmosphere such as argon. Advantageously, the graphite reinforcement material is whiskered prior to combining it with the matrix mixture by a novel method involving passing a gaseous metal suboxide over the graphite surface.