An example method includes combining an interlayer and a carbon fiber fabric, wherein the interlayer comprises a highly oriented milled carbon fiber ply comprising a plurality of out-of-plane carbon fibers. The method further includes winding the interlayer and the carbon fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.

An example method includes forming an interlayer on a carbon fiber fabric to form a composite fiber fabric. The interlayer comprises a binder. The method further includes winding the composite fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.

An example method includes forming an interlayer on a carbon fiber fabric to form a composite fiber fabric. The interlayer comprises a binder. The method further includes winding the composite fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.

A system and method for enhancing a diffusion limited CVI/CVD process is provided. The system may densify a porous structure by flowing a reactant gas around the porous structure. A mass flow controller may be configured to pulse the flow rate of the reactant gas around the porous structure. The mass flow controller may pulse the flow rate from a nominal flow rate to a first flow rate. The mass flow controller may pulse the first flow rate back to the nominal flow rate or to a second flow rate. The mass flow controller may pulse the flow rate between the nominal flow rate, the first flow rate, and the second flow rate, as desired.

A system and method for enhancing a diffusion limited CVI/CVD process is provided. The system may densify a porous structure by flowing a reactant gas around the porous structure. A mass flow controller may be configured to pulse the flow rate of the reactant gas around the porous structure. The mass flow controller may pulse the flow rate from a nominal flow rate to a first flow rate. The mass flow controller may pulse the first flow rate back to the nominal flow rate or to a second flow rate. The mass flow controller may pulse the flow rate between the nominal flow rate, the first flow rate, and the second flow rate, as desired.

A method for forming an oxidation protection system on a composite structure is provided, which may comprise applying a ceramic layer slurry to the composite structure, wherein the ceramic layer slurry may comprise aluminum and silicon in a solvent or carrier fluid; heating the composite structure to form a ceramic layer on the composite structure, wherein the ceramic layer may comprise aluminum nitride; applying a sealing slurry to the composite structure, wherein the sealing slurry may comprise a sealing pre-slurry composition and a sealing carrier fluid, wherein the sealing pre-slurry composition may comprise a sealing phosphate glass composition; and/or heating the composite structure to form a sealing layer on the composite structure.

A method for forming an oxidation protection system on a composite structure is provided, which may comprise applying a ceramic layer slurry to the composite structure, wherein the ceramic layer slurry may comprise aluminum and silicon in a solvent or carrier fluid; heating the composite structure to form a ceramic layer on the composite structure, wherein the ceramic layer may comprise aluminum nitride; applying a sealing slurry to the composite structure, wherein the sealing slurry may comprise a sealing pre-slurry composition and a sealing carrier fluid, wherein the sealing pre-slurry composition may comprise a sealing phosphate glass composition; and/or heating the composite structure to form a sealing layer on the composite structure.

A method of fabricating a gas turbine casing out of composite material of varying thickness, the method including making a strip-shaped fiber texture by three-dimensional weaving; winding the fiber texture as a plurality of superposed layers onto a mandrel of profile corresponding to the profile of the casing that is to be fabricated, so as to obtain a fiber preform of shape corresponding to the shape of the casing that is to be fabricated; and densifying the fiber preform with a matrix; wherein, before beginning to wind the fiber texture onto the mandrel, a reinforcing band of width smaller than the width of the fiber texture is placed on the mandrel in a zone that is to form a retention zone of the casing.

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.

Systems and methods for forming an oxidation protection system on a composite structure are provided. In various embodiments, an oxidation protection system disposed on a substrate may comprise a boron-silicon-glass layer formed directly on the composite structure. The boron-silicon-glass layer may comprise a boron compound, a silicon compound, and a glass compound.