C04B2235/3804

Method of fabricating a ceramic matrix composite including a dip coating process

A method of making a ceramic matrix composite (CMC) having an increased carbon content that may show improved resistance to chemical attack from molten silicon is described. The method includes depositing one or more matrix layers comprising boron nitride, silicon nitride, pyrolytic carbon, and/or silicon carbide on a fiber preform comprising one or more silicon carbide fibers. After depositing the matrix layer, the fiber preform is dipped into a coating solution comprising a polymer to deposit a polymeric layer on the matrix layer. After dip coating, the fiber preform is infiltrated with a slurry comprising ceramic particles and/or carbon particles to form a green body; after forming the green body, the polymeric layer is pyrolyzed to form a carbon-containing coating on the matrix layer; and the green body is then infiltrated with a melt comprising silicon or silicon alloy. Upon cooling the melt, a dense CMC formed may be obtained.