The present invention describes various aspects of an inexpensive, renewable and sustainable particulate material system which is basically composed of one or more carbon precursor materials and other powder-based constituents. There is also an in-detail description of the composition of the preferred particulate material system and steps involved in manufacturing high-performance carbon composite articles using commercial binder jetting powder-based 3D printers. The preferred particulate material system composition of the present invention can be equal in performance to typical binder jetting 3D printing powders but much less expensive.

The present invention describes various aspects of an inexpensive, renewable and sustainable particulate material system which is basically composed of one or more carbon precursor materials and other powder-based constituents. There is also an in-detail description of the composition of the preferred particulate material system and steps involved in manufacturing high-performance carbon composite articles using commercial binder jetting powder-based 3D printers. The preferred particulate material system composition of the present invention can be equal in performance to typical binder jetting 3D printing powders but much less expensive.

Provided is a C/C composite having a long life in an environment including a heating process and a cooling process and having less adverse effects on surrounding facilities and the quality of treatment objects. A C/C composite in which, in measurement for open pores by mercury porosimetry, an open porosity for open pores with a radius of not less than 0.4 μm and less than 10 μm in the C/C composite is 2.0% or less.

Provided is a C/C composite having a long life in an environment including a heating process and a cooling process and having less adverse effects on surrounding facilities and the quality of treatment objects. A C/C composite in which, in measurement for open pores by mercury porosimetry, an open porosity for open pores with a radius of not less than 0.4 μm and less than 10 μm in the C/C composite is 2.0% or less.

Provided is a C/C composite having a long life in an environment including a heating process and a cooling process and having less adverse effects on surrounding facilities and the quality of treatment objects. A C/C composite in which, in measurement for open pores by mercury porosimetry, an open porosity for open pores with a radius of not less than 0.4 μm and less than 10 μm in the C/C composite is 2.0% or less.

A method for making a carbon carbon, carbon ceramic matrix, or carbon silica composite, comprising melt processing a resin comprising a polyaryletherketone (PAEK) and at least one reinforcing additive to make a precursor part, pyrolyzing the precursor part to make a pyrolyzed part, infusing a liquid second resin into the pyrolyzed part to make an infused part, and pyrolyzing the infused part. Other methods comprise processing aligned reinforcing additives and a resin comprising a PAEK to make an aligned reinforcing additives PAEK, aligned 1-2 dimensional flake material, or aligned 1-2 dimensional platelet material, to create a fabric, prepreg or tape comprising the aligned reinforcing additives and impregnated PAEK. Other methods comprise impregnating continuous fiber tape or fabric with a resin comprising PAEK and at least one reinforcing additive or co-weaving a continuous fiber or fabric with a PAEK fiber comprising PAEK and at least one reinforcing additive.

A method for making a carbon carbon, carbon ceramic matrix, or carbon silica composite, comprising melt processing a resin comprising a polyaryletherketone (PAEK) and at least one reinforcing additive to make a precursor part, pyrolyzing the precursor part to make a pyrolyzed part, infusing a liquid second resin into the pyrolyzed part to make an infused part, and pyrolyzing the infused part. Other methods comprise processing aligned reinforcing additives and a resin comprising a PAEK to make an aligned reinforcing additives PAEK, aligned 1-2 dimensional flake material, or aligned 1-2 dimensional platelet material, to create a fabric, prepreg or tape comprising the aligned reinforcing additives and impregnated PAEK. Other methods comprise impregnating continuous fiber tape or fabric with a resin comprising PAEK and at least one reinforcing additive or co-weaving a continuous fiber or fabric with a PAEK fiber comprising PAEK and at least one reinforcing additive.

A method for forming an oxidation protection system on a composite structure may comprise: applying a ceramic layer slurry to the composite structure, wherein the ceramic layer slurry comprises aluminum and silicon in a solvent or carrier fluid; and heating the composite structure in an environment comprising nitrogen gas and oxygen gas to form a ceramic layer on the composite structure, wherein the ceramic layer comprises aluminum nitride and alumina.

A method for forming an oxidation protection system on a composite structure may comprise: applying a ceramic layer slurry to the composite structure, wherein the ceramic layer slurry comprises aluminum and silicon in a solvent or carrier fluid; and heating the composite structure in an environment comprising nitrogen gas and oxygen gas to form a ceramic layer on the composite structure, wherein the ceramic layer comprises aluminum nitride and alumina.

A method of chemical vapor infiltration and deposition includes disposing a porous substrate within a reaction chamber, establishing a sub-atmospheric pressure within the reaction chamber, introducing a hydrocarbon reaction gas into a reaction zone of the reaction chamber to densify the porous substrate, withdrawing unreacted hydrocarbon reaction gas from the reaction chamber, the unreacted hydrocarbon reaction gas comprising hydrocarbon molecules having six or more carbon atoms, removing at least a portion of the hydrocarbon molecules having six or more carbon molecules from the unreacted hydrocarbon reaction gas by causing the portion of the hydrocarbon molecules having six or more carbon atoms to condense, and recirculating at least a portion of the unreacted hydrocarbon reaction gas back into the reaction zone.