General Electric Company

E.i. Dupont De Nemours and Company

Honeywell International Inc.

Rohr, Inc.

Lanxide Technology Company, LP

Du Pont Lanxide Composites L.p.

Alliedsignal Composites Inc.

Honeywell Advanced Composites Inc.

Paul Edward Gray

Glenn Curtis Taxacher

Herbert Chidsey Roberts, Iii

Philip Harold Monaghan

Herbert Chidsey Roberts

Peter De Diego

Timothy P Coons

Roger Lee Ken Matsumoto

Nicholas Frederick Wendeln

Sheena Kum Foster Walker

Mark Henry Headinger

Jeffrey H Boy

Joseph Halada

Joseph John Nick

Sheena Kum Walker

Herbert Chidsey Roberts Lll

A system and method of melt infiltrating components is provided. In one example aspect, an inductive heating system includes a heating source that inductively heats a susceptor. The susceptor defines a working chamber in which components can be received. During melt infiltration, the system can heat the susceptor and thus the components and melt infiltrants disposed within the working chamber at a first heating rate. The first heating rate can be faster than 50&#xb0; C./minute. The system can then heat the components and melt infiltrants at a second heating rate. The first heating rate is faster than the second heating rate. Thereafter, the system can heat the components and infiltrants at a third heating rate. The third heating rate can be a constant rate at or above the melting point of the melt infiltrants. The infiltrants can melt and thus infiltrate into the component to densify the component.

Induction melt infiltration processing of ceramic matrix composite components

A process for producing an internal cavity in a CMC article and mandrels used therewith. The process entails incorporating a mandrel made of a material that is substantially absorbed during thermal treatment of a preform to form the CMC article. The mandrel material is preferably reactive with one or more constituents of the CMC preform during the thermal treatment. The material is preferably silicon or a silicon alloy.

Method of producing an internal cavity in a ceramic matrix composite and mandrel therefor

A process for producing an internal cavity in a CMC article and mandrels used therewith. The process entails incorporating a mandrel made of a fusible material that is melted and drained during a thermal treatment of a CMC preform to form the CMC article. The mandrel material is preferably non-wetting and non-reactive with any constituents of the CMC preform during the thermal treatment. The mandrel is preferably tin or an alloy of tin.

Method of producing an internal cavity in a ceramic matrix composite

Systems, methods and devices adapted to ease manufacture of composite articles (e.g., ceramic composite articles), particularly composite articles which include a hollow feature are disclosed. In one embodiment, a system includes: a consumable core formed to be disposed within an inner portion of a composite precursor, the consumable core adapted to convert into an infiltrant during a manufacturing process and infiltrate the composite precursor.

Consumable core for manufacture of composite articles and related method

In certain embodiments of the present disclosure a method for modifying a composite article is described. The method includes positioning a plug made from composite material at a site on the composite article. The method further includes rotating at least one of the plug and the article at a rate of speed sufficient to form an inertia bond between the plug and the site of the composite article. The plug and the site are engaged to effect an inertia bond therebetween.

Method for modifying composite articles

A method of producing a CMC article having a net shape, and by which the article can be formed to have an exterior surface with desirable characteristics, such as being free of an imprint pattern of a fiber reinforcement material within the article. The method entails providing a body comprising the fiber reinforcement material, and depositing a coating on a surface of the body. The coating contains a carbonaceous binder and a slurry containing a ceramic particulate material. Following its deposition, the carbonaceous binder within the coating is cured to render the coating machinable, and the coating is then machined to approximately produce the net shape of the article.

Method of producing a ceramic matrix composite article

Carbon-silicon carbide brake preforms are manufactured by carbonizing a blend of carbon (e.g., polyacrylonitrile) fibers and thermosetting pitch resin, optionally along with a lubricant such as graphite,.to provide an intermediate product having open porosity and subsequently filling the pores of the intermediate product with silicon by a melt infiltration process. Molded articles that consist principally of carbon, that have relatively high strength and resistance to decomposition by frictional heat, and that are suitable for melt infiltration with silicon, are produced by, e.g.: coating randomly oriented polyacrylonitrile-derived carbon fibers, optionally mixed with finely divided carbon powder, with a thermosetting blend of (a) pitch and (b) an organic medium, at an elevated temperature to form a viscous molding compound; molding the compound at a low pressure and elevated temperature so that a solid compact is obtained; stripping a molded article made of said compound from the mold; optionally heating the molded article at gradually increasing temperatures to insure complete condensation within the article; and carbonizing the condensed molded article in an inert atmosphere at gradually increasing temperatures to produce a molded C/C intermediate article suitable for melt-infiltration with silicon. The preforms may be configured in the form of a disc brake rotor or a disc brake pad.

Process for manufacturing friction material suitable for use as brake lining

Carbon-silicon carbide brake preforms are manufactured by carbonizing a blend of carbon (e.g., polyacrylonitrile) fibers and thermosetting pitch resin, optionally along with a lubricant such as graphite, to provide an intermediate product having open porosity and subsequently filling the pores of the intermediate product with silicon by a melt infiltration process. Molded articles that consist principally of carbon, that have relatively high strength and resistance to decomposition by frictional heat, and that are suitable for melt infiltration with silicon, are produced by, e.g.: coating randomly oriented polyacrylonitrile-derived carbon fibers, optionally mixed with finely divided carbon powder, with a thermosetting blend of (a) pitch and (b) an organic medium, at an elevated temperature to form a viscous molding compound; molding the compound at a low pressure and elevated temperature so that a solid compact is obtained; stripping a molded article made of said compound from the mold; optionally heating the molded article at gradually increasing temperatures to insure complete condensation within the article; and carbonizing the condensed molded article in an inert atmosphere at gradually increasing temperatures to produce a molded C/C intermediate article suitable for melt-infiltration with silicon. The preforms may be configured in the form of a disc brake rotor or a disc brake pad.

Melt-infiltrated pitch-pan preforms

The invention provides for oxidatively resistant surface coated carbon/carbon composites and other graphite-like material, a method for the preparation of these materials, and their use in high temperature applications, preferably in brake for airplanes. The surface coated carbon/carbon composite or graphite-like material, which is resistant to oxidation at high temperatures comprises a fiber-reinforced carbon/carbon composite or graphite having a First Coating (A) of silicon and/or silicon carbide, and a Second Coating (B) comprising a material containing phosphorus chemically bound to oxygen which is chemically bound to silicon.

Oxidation protection for carbon/carbon composite and graphite friction materials

The present invention relates to porous mat gas fired radiant burner panels utilizing improved reverberatory screens. The purpose of these screens is to boost the overall radiant output of the burner relative to a burner using no screen and the same fuel-air flow rates. In one embodiment, the reverberatory screen is fabricated from ceramic composite material, which can withstand higher operating temperatures than its metallic equivalent. In another embodiment the reverberatory screen is corrugated. The corrugations add stiffness which helps to resist creep and thermally induced distortions due to temperature or thermal expansion coefficient differences. As an added benefit, it has been unexpectedly discovered that the corrugations further increase the radiant efficiency of the burner. In a preferred embodiment, the reverberatory screen is both corrugated and made from ceramic composite material.

Reverberatory screen for a radiant burner

A ceramic fiber reinforced filter is prepared by depositing a thin filtration layer of preselected pore size on a more porous ceramic support. The filter is characterized by a low pressure drop across the filtration layer in operation and easy back pressure pulse cleaning.

Ceramic fiber reinforced filter

Carbon or ceramic matrix composites are protected from oxidation at high temperatures by a layer formed from a mixture of solid particles in a binder which is cured and then coated with ceramic material by chemical vapor infiltration.

Coating a composite article by applying a porous particulate layer and

An attachment fitting for securing metal structures to carbon-carbon structures which tightens as temperature increases. The fitting is particularly useful in high temperature aerospace applications such as hypersonic aircraft. The fitting basically connects an upstanding carbon-carbon blade on a carbon-carbon structure to a metal clevis which fits snugly thereover. A ceramic bushing is fitted in a transverse hole in the blade. A transverse bolt hole extends through the clevis and bushing. A bolt in the bolt hole is tightened with one or more nuts to tightly press the clevis against the busing and blade. The bolt and nut material is selected to have a lower coefficient of thermal expansion than the clevis so that differential thermal expansion between clevis and bolt keeps the joint tight at elevated temperatures.

Self-tightening fitting for attachment of metal to carbon-carbon

Ceramic matrix composites having a boron containing oxygen-scavenging sealant-forming region coextensive with the internal fibers and interface debonding layer and a ceramic matrix material provide superior resistance to oxidation.

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North East, MD, United States of America

Paul Edward Gray