Boron carbide ceramic fibers

Abstract

A metal carbide ceramic fiber having improved mechanical properties and characteristics and improved processes and chemical routes for manufacturing metal carbide ceramic fiber. Metal carbide ceramic fibers may be formed via reaction bonding of a metal-based material (e.g. boron) with the inherent carbon of a carrier medium. One embodiment includes a method of making a metal carbide ceramic fiber using VSSP to produce high yield boron carbide fiber. Embodiments of the improved method allow high volume production of high density boron carbide fiber. The chemical routes may include a direct production of boron carbide fiber from boron carbide powder (BC) and precursor (e.g. rayon fiber) having a carbon component to form a BC/rayon fiber that may be processed at high temperature to form boron carbide fiber, and that may be subsequently undergo a hot isostatic pressing to improve fiber purity. Another route may include a carbothermal method comprising combining boron powder (B) with a precursor (e.g., rayon fiber) having a carbon component to form a B/rayon fiber, carbonizing and a chemical reaction of boron (B) and carbon (C) to form boron carbide fiber. Another carbothermal method may comprise combining boron oxide powder (BO) with a precursor (e.g., rayon fiber) having a carbon component to form a BO/rayon fiber, carbonizing and a chemical reaction of boron oxide (BO) and carbon (C) to form boron carbide (BC) fiber.