Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

A method for constructing multiple ceramic layers by winding continuous ceramic filaments of different compositions to prepare multilayer RF-transparent structures is provided. In the method, different continuous ceramic filaments are braided to construct layers with specific dielectric constants and braiding count/thickness. Layers with same or different dielectric characteristics forms a sandwich design to fulfill the desired mechanical, thermal and electrical requirements.

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

Composite materials and methods of manufacturing composite materials, such as for use in aerospace parts, are described herein. A representative method for manufacturing a coated composite material structure includes applying a plurality of material layers to a preform structure. The plurality of material layers can include at least one first material layer (including a first matrix precursor), and at least one second material layer (including a second matrix precursor and a coating precursor). The method can also include infusing the preform structure with the first and second matrix precursors and the coating precursor from the plurality of material layers. The method can further include heating the infused preform structure to concurrently form a composite material structure and a coating on at least a portion of the composite material structure.

A preform for making a component of a braking system having a fibre-reinforced ceramic composite material, obtained by forming and subsequent pyrolysis of a pre-preg is described. Also described is a component of a braking system made wholly or in part from the preform, and a method for making a preform in a fibre-reinforced ceramic composite material.

A method for forming a complex shape three-dimensional ceramic article by printing a first layer of a first material having a first fraction of first ceramic particles and a first fraction of a first polymeric ceramic precursor. A second layer is printed such that it is at least partially disposed on the first layer of a second material having a second fraction of second ceramic particles and a second fraction of a second polymeric ceramic precursor. A composite of the first layer and the second layer is heated at a temperature sufficient to decompose the first and second polymeric ceramic precursors and sinter the article. During the sintering process, the first and second layers with different fractions of ceramic particles undergo different degrees of shrinkage, resulting in a tuneable mismatch of the bilayer structure and accurately achieving a targeted geometry.

A method for forming a complex shape three-dimensional ceramic article by printing a first layer of a first material having a first fraction of first ceramic particles and a first fraction of a first polymeric ceramic precursor. A second layer is printed such that it is at least partially disposed on the first layer of a second material having a second fraction of second ceramic particles and a second fraction of a second polymeric ceramic precursor. A composite of the first layer and the second layer is heated at a temperature sufficient to decompose the first and second polymeric ceramic precursors and sinter the article. During the sintering process, the first and second layers with different fractions of ceramic particles undergo different degrees of shrinkage, resulting in a tuneable mismatch of the bilayer structure and accurately achieving a targeted geometry.