Ply layups and methods for forming composite components are provided. For example, a method for forming a composite component comprises laying up a plurality of composite plies to form a composite ply layup; partially processing the composite ply layup to form a green state layup; machining the green state layup; assembling the green state layup with one or more sub-assemblies; and processing the green state layup and the one or more sub-assemblies to form the composite component. In an exemplary embodiment, the composite component is a turbine nozzle airfoil. Another exemplary method comprises laying up a plurality of composite plies to form a composite ply layup; compacting the composite ply layup to form a green state layup; machining the green state layup; assembling the green state layup with one or more sub-assemblies; and processing the green state layup and the one or more sub-assemblies to form the composite component.

A thin-film thermocouple for measuring the temperature of a ceramic matrix composite (CMC) component includes a first thermocouple leg and a second thermocouple leg deposited on a surface of a CMC component, where each of the first and second thermocouple legs has a length extending from a reference end to a working end thereof. The working ends of the first and second thermocouple legs are joined at a junction region on the surface. At least one of the first thermocouple leg and the second thermocouple leg comprises silicon carbide.

A turbine component assembly is disclosed, including a first component, a second component, and an interface shield. The first component is arranged to be disposed adjacent to a hot gas path, and includes a ceramic matrix composite composition. The second component is adjacent to the first component and arranged to be disposed distal from the hot gas path across the first component. The interface shield is disposed on a contact region of the first component, and directly contacts the second component.

An improved method for embedding one or more sensors in SiC is provided. The method includes depositing a binder onto successive layers of a SiC powder feedstock to produce a dimensionally stable green body have a true-sized cavity. A sensor component is then press-fit into the true-sized cavity. Alternatively, the green body is printed around the sensor component. The assembly (the green body and the sensor component) is heated within a chemical vapor infiltration (CVI) chamber for debinding, and a precursor gas is introduced for densifying the SiC matrix material. During infiltration, the sensor component becomes bonded to the densified SiC matrix, the sensor component being selected to be thermodynamically compatible with CVI byproducts at elevated temperatures, including temperatures in excess of 1000? C.

A ceramic matrix composite laminate comprises a ceramic matrix that encapsulates a plurality of layers. Each layer comprises fibers. Each layer comprises a plurality of fill fibers and a plurality of warp fibers or a plurality of bias fibers. The outermost layer contains a different concentration of fibers per unit volume than a layer located near an interior of the ceramic matrix composite laminate. A gradient in the number of fibers exists between the outermost layer and the layer located at the interior of the ceramic matrix composite laminate, or a combination thereof. A combined ceramic matrix composite comprises a plurality of composite laminates; wherein each laminate has a different fiber concentration gradient from another laminate that it is in contact with.

A preform comprising a first sub-laminate comprising a plurality of layers and a second sub-laminate comprising a plurality of layers. The first sub-laminate comprises a first unit cell comprising a first volume fraction of tows, where the first volume fraction of tows comprise first tows having a first tow spacing between successive first tows. The second sub-laminate comprises a second unit cell comprising a second volume fraction of tows, where the second volume fraction of tows comprise second tows having a second tow spacing between successive second tows. The first volume fraction of tows in the first unit cell is equal to the second volume fraction of tows in the second unit cell. The second tow spacing is less than the first tow spacing.

A ceramic composite tubular structure includes a monolithic ceramic preform being tubular-shaped created using an additive manufacturing process. The monolithic ceramic preform includes a first end, a second end, an inner surface, and an outer surface. The monolithic ceramic preform includes one or more apertures formed between the inner surface and the outer surface where at least one of the one or more apertures is open to at least one of the first end or the second end. An inner face sheet is formed on the inner surface of the monolithic ceramic preform by a first quantity of ceramic matrix composite plies. An outer face sheet is formed on the outer surface of the monolithic ceramic preform by a second quantity of ceramic matrix composite plies.

A method for manufacturing an abradable layer and a substrate coated with this layer, may include: preparing a powder composition including at least ceramic particles and an inorganic filler having a lamellar crystallographic structure, the volume content of the inorganic filler in the powder composition being in a range of from 1 to 75%; compressing the powder composition; and sintering the powder composition thus compressed in order to obtain the abradable layer.

An abradable coating includes a tubular cell structure, wherein the the tubular cell structure includes a fibrous reinforcement of discontinuous short fibers which is densified by a ceramic matrix.

A honeycomb body made of a composite material for fire-resistant lightweight structures including honeycomb cells having a cross section is provided. The cell walls of the honeycomb cells are produced from a composite material. The composite material has at least one carrier, for example a woven fabric or a laid fabric made of fibers, and a matrix into which the carrier is embedded. The matrix includes a silicon-based ceramic material, of which the proportion by mass in the matrix along the cell walls is at least 30 wt. %. A method for producing such a ceramic honeycomb body and a honeycomb tube as an intermediate product for the same are also provided. A flat semi-finished product as a curable intermediate product for the production of fire-resistant fiber composite lightweight structures, which has a matrix mixture including dispersed silicon particles, is also provided.