A method of making a ceramic matrix composite (CMC) that may show improved resistance to chemical attack from molten silicon along with excellent mechanical strength is described. The method includes forming an interphase coating on one or more silicon carbide fibers, depositing a matrix layer comprising silicon carbide on the interphase coating, oxidizing the matrix layer to form an oxidized film comprising silicon oxide, depositing a wetting layer comprising silicon carbide on the oxidized film. After depositing the wetting layer, a fiber preform containing the silicon carbide fibers is heat treated. After the heat treatment, the fiber preform is infiltrated with a slurry. After infiltration with the slurry, the fiber preform is infiltrated with a melt containing silicon, and then the melt is cooled to form a ceramic matrix composite.

A method of making a ceramic matrix composite (CMC) that may show improved resistance to chemical attack from molten silicon along with excellent mechanical strength is described. The method includes forming an interphase coating on one or more silicon carbide fibers, depositing a matrix layer comprising silicon carbide on the interphase coating, oxidizing the matrix layer to form an oxidized film comprising silicon oxide, depositing a wetting layer comprising silicon carbide on the oxidized film. After depositing the wetting layer, a fiber preform containing the silicon carbide fibers is heat treated. After the heat treatment, the fiber preform is infiltrated with a slurry. After infiltration with the slurry, the fiber preform is infiltrated with a melt containing silicon, and then the melt is cooled to form a ceramic matrix composite.

A process for the manufacture of a refractory block including more than 80% zirconia, in percentage by weight based on the oxides. The process includes the following successive stages: melting, under reducing conditions, of a charge including more than 50% zircon, in percentage by weight, such as to reduce the zircon and obtain a molten material, application of oxidizing conditions to the molten material, casting of the molten material, and cooling until at least partial solidification of the molten material in the form of a block. Also, the process can include heat treatment of the block.

A process for the manufacture of a refractory block including more than 80% zirconia, in percentage by weight based on the oxides. The process includes the following successive stages: melting, under reducing conditions, of a charge including more than 50% zircon, in percentage by weight, such as to reduce the zircon and obtain a molten material, application of oxidizing conditions to the molten material, casting of the molten material, and cooling until at least partial solidification of the molten material in the form of a block. Also, the process can include heat treatment of the block.

A ceramic matrix composite (CMC) component and method of fabrication including one or more elongate functional features formed in multiple fiber plies of the CMC component. The CMC component includes a plurality of longitudinally extending ceramic matrix composite plies in a stacked configuration. Each of the one or more elongate functional features includes an inlet and an outlet to provide a flow of fluid from a fluid source to an exterior of the ceramic matrix composite component. The one or more elongate functional features are configured in multiple plies of the plurality of longitudinally extending ceramic matrix composite plies to form a plurality of cooling channels in multiple plies of the ceramic matrix composite component.

A ceramic matrix composite (CMC) component and method of fabrication including one or more elongate functional features formed in multiple fiber plies of the CMC component. The CMC component includes a plurality of longitudinally extending ceramic matrix composite plies in a stacked configuration. Each of the one or more elongate functional features includes an inlet and an outlet to provide a flow of fluid from a fluid source to an exterior of the ceramic matrix composite component. The one or more elongate functional features are configured in multiple plies of the plurality of longitudinally extending ceramic matrix composite plies to form a plurality of cooling channels in multiple plies of the ceramic matrix composite component.

A fiber reinforced composite component may include interleaved fiber layers and ceramic particle layers coated with matrix material. The fiber reinforced composite component may be fabricated by forming a fibrous preform, needling the fibrous preform to form a plurality of z-direction fibers, and densifying the fibrous preform. The fibrous preform may be fabricated by forming a first ceramic particle layer over a first fiber layer, disposing a second fiber layer over the first ceramic particle layer, forming a second ceramic particle layer over the second fiber layer, and disposing a third fiber layer over the second ceramic particle layer.

A fiber reinforced composite component may include interleaved fiber layers and ceramic particle layers coated with matrix material. The fiber reinforced composite component may be fabricated by forming a fibrous preform, needling the fibrous preform to form a plurality of z-direction fibers, and densifying the fibrous preform. The fibrous preform may be fabricated by forming a first ceramic particle layer over a first fiber layer, disposing a second fiber layer over the first ceramic particle layer, forming a second ceramic particle layer over the second fiber layer, and disposing a third fiber layer over the second ceramic particle layer.

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° 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.

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° 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.