A method for producing graphene, configured for forming a graphene layer on a surface of an object. The method includes steps of: depositing a poly-p-xylene material layer on the surface: and converting the poly-p-xylene material layer into a graphene layer by using a laser sintering process or a plasma-assisted sintering process.

The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp during the transferring the carbon short fibers. The base layer may comprise an annular shape.

Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided.

Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided.

A method for forming a patch repair on a silicon-based component is disclosed. The method includes applying a patch on a damaged area of a silicon-based component, drying the patch to form a dried patch, and sintering in situ the dried patch to form a patch repaired portion of the silicon-based component. The patch includes a patching material and the patching material includes a plurality of nanoparticles having a median particle size less than 100 nanometers. The plurality of nanoparticles includes at least one of silicon, silicon alloy, silica, or a metal silicate.

A method for forming a patch repair on a silicon-based component is disclosed. The method includes applying a patch on a damaged area of a silicon-based component, drying the patch to form a dried patch, and sintering in situ the dried patch to form a patch repaired portion of the silicon-based component. The patch includes a patching material and the patching material includes a plurality of nanoparticles having a median particle size less than 100 nanometers. The plurality of nanoparticles includes at least one of silicon, silicon alloy, silica, or a metal silicate.

The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp during the transferring the carbon short fibers. The base layer may comprise an annular shape.

A tooling fixture is disclosed for densification by chemical vapor infiltration of a fiber preform of a ceramic matrix composite. The tooling fixture includes a body having oppositely disposed first and second surfaces and a plurality of holes extending between the first and second surfaces, and a coating. The first surface is configured to be disposed adjacent to the fiber preform. The coating is disposed on the first surface and surfaces defining the plurality of holes. The coating comprises at least one of a ceramic material, hexagonal boron nitride, turbostratic boron nitride, and graphite.

A tooling fixture is disclosed for densification by chemical vapor infiltration of a fiber preform of a ceramic matrix composite. The tooling fixture includes a body having oppositely disposed first and second surfaces and a plurality of holes extending between the first and second surfaces, and a coating. The first surface is configured to be disposed adjacent to the fiber preform. The coating is disposed on the first surface and surfaces defining the plurality of holes. The coating comprises at least one of a ceramic material, hexagonal boron nitride, turbostratic boron nitride, and graphite.

A method of producing a ceramic matrix composite including a protective ceramic coating thereon comprises applying a surface slurry onto an outer surface of an impregnated fiber preform. The surface slurry includes particulate ceramic solids dispersed in a flowable preceramic polymer comprising silicon, and the impregnated fiber preform comprises a framework of ceramic fibers loaded with particulate matter. The flowable preceramic polymer is cured, thereby forming on the outer surface a composite layer comprising a cured preceramic polymer with the particulate ceramic solids dispersed therein. The cured preceramic polymer is then pyrolyzed to form a porous ceramic layer comprising silicon carbide, and the impregnated fiber preform and the porous ceramic layer are infiltrated with a molten material comprising silicon. After infiltration, the molten material is cooled to form a ceramic matrix composite body with a protective ceramic coating thereon.