General Atomics, Inc.

James E Sheehan

Holger H Streckert

Khodabakhsh S Mazdiyasni

A method for producing shapes utilizing carbon-based fiber cloth materials embedded in silicon carbide matrices. Boron compound is applied to a preform which may be a plurality of carbon fiber sheets in a stack or which may be a complex three dimensional structure, such as a braided tube or a woven fiber network with filaments running in a plurality of different directions. Alternatively, individual sheets can be treated and then stacked or otherwise formed into a preform. Boron is applied in a form in which it serves as a wetting/bonding agent. The preform or each of the sheets is then impregnated with a polysilane resin. If sheets are used, the sheets are then stacked in mating face-to-face relationships in a desired preform shape. Thereafter, the preform is heated in a first heating step to a temperature sufficient to cross-link the polysilane, and then heated in a second heating step to a temperature sufficient to transform the crosslinked resin into a silicon carbide matrix having the carbon fiber network embedded therein.

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Solana Beach, CA, United States of America

James E Sheehan