A ceramic matrix composite (CMC) component and method of fabrication including a plurality of counterflow elongated functional features. The CMC component includes a plurality of longitudinally extending ceramic matrix composite plies forming a densified body and a plurality of elongated functional features formed therein the densified body. Each of the plurality of functional features is configured longitudinally extending and in alignment with the plurality of ceramic matrix composite plies. Each of the plurality of elongated functional features includes an inlet configured in cross-ply configuration. The plurality of elongated functional features are configured to provide a flow of fluid from a fluid source to an exterior of the ceramic matrix composite component. The plurality of functional features are configured in alternating flow configuration.

A ceramic matrix composite (CMC) component and method of fabrication including a plurality of counterflow elongated functional features. The CMC component includes a plurality of longitudinally extending ceramic matrix composite plies forming a densified body and a plurality of elongated functional features formed therein the densified body. Each of the plurality of functional features is configured longitudinally extending and in alignment with the plurality of ceramic matrix composite plies. Each of the plurality of elongated functional features includes an inlet configured in cross-ply configuration. The plurality of elongated functional features are configured to provide a flow of fluid from a fluid source to an exterior of the ceramic matrix composite component. The plurality of functional features are configured in alternating flow configuration.

A fiber powder having a 50% particle diameter (d.sub.50) of 6 to 60 μm, characterized in that the fiber powder has a maximum particle diameter (d.sub.100) of 1,000 μm or less. It is preferred that a value ((d.sub.10.Math.d.sub.90)/d.sub.100) obtained by dividing by the maximum particle diameter (d.sub.100) a value which is obtained by multiplying a 10% particle diameter (d.sub.10) by a 90% particle diameter (d.sub.90) is 0.3 to 5.0, that the fiber powder has an extractable component content of 0.2 to 3.0% by weight based on the fiber weight, and that the fiber powder has a water content of 0.2 to 50% by weight. Further, it is preferred that the fiber powder is an organic material, or comprises a thermoplastic resin, and that the thermoplastic resin is a polyester resin or a polyamide resin.

A fiber powder having a 50% particle diameter (d.sub.50) of 6 to 60 μm, characterized in that the fiber powder has a maximum particle diameter (d.sub.100) of 1,000 μm or less. It is preferred that a value ((d.sub.10.Math.d.sub.90)/d.sub.100) obtained by dividing by the maximum particle diameter (d.sub.100) a value which is obtained by multiplying a 10% particle diameter (d.sub.10) by a 90% particle diameter (d.sub.90) is 0.3 to 5.0, that the fiber powder has an extractable component content of 0.2 to 3.0% by weight based on the fiber weight, and that the fiber powder has a water content of 0.2 to 50% by weight. Further, it is preferred that the fiber powder is an organic material, or comprises a thermoplastic resin, and that the thermoplastic resin is a polyester resin or a polyamide resin.

Batch compositions containing pre-reacted inorganic spheroidal particles, small amount of fine inorganic particles (“fines”), and an extremely large amount of liquid vehicle. The batch compositions contain pre-reacted inorganic particles having a particle size distribution with 20 μm≤D50≤100 μm, D90≤100 μm, and D5≥10 μm; less than 20 wt % of fine inorganic particles (fines) whose particle distribution(s) have a median diameter of less than 5 μm; and a liquid vehicle in a weight percent (LV %≥28%) by super-addition to all inorganic particles in the batch composition. Fast extruding batch compositions having extremely high Tau Y/Beta ratios are provided. Green bodies, such as green honeycomb bodies and methods of manufacturing green honeycomb bodies are provided, as are other aspects.

Batch compositions containing pre-reacted inorganic spheroidal particles, small amount of fine inorganic particles (“fines”), and an extremely large amount of liquid vehicle. The batch compositions contain pre-reacted inorganic particles having a particle size distribution with 20 μm≤D50≤100 μm, D90≤100 μm, and D5≥10 μm; less than 20 wt % of fine inorganic particles (fines) whose particle distribution(s) have a median diameter of less than 5 μm; and a liquid vehicle in a weight percent (LV %≥28%) by super-addition to all inorganic particles in the batch composition. Fast extruding batch compositions having extremely high Tau Y/Beta ratios are provided. Green bodies, such as green honeycomb bodies and methods of manufacturing green honeycomb bodies are provided, as are other aspects.

A method of producing a ceramic matrix composite component. The method includes positioning a first plurality of ceramic matrix composite plies on top of one another, disposing a filler pack on the first plurality of ceramic matrix composite plies, and positioning a second plurality of ceramic matrix composite plies on top of the filler pack. One of the first plurality of ceramic composite plies or the second plurality of ceramic composite plies includes a bend angle, to define an interstice between the plurality of ceramic matrix composite plies with the filler pack disposed in the interstice. The filler pack includes one or more sacrificial fibers disposed therein, that subsequent to removal provide a functional feature, such as a cooling manifold in the filler pack. The method further includes forming one or more channels coupled to the one or more functional features for the flow of a cooling fluid therethrough. A ceramic matrix composite is also disclosed.

A method of producing a ceramic matrix composite component. The method includes positioning a first plurality of ceramic matrix composite plies on top of one another, disposing a filler pack on the first plurality of ceramic matrix composite plies, and positioning a second plurality of ceramic matrix composite plies on top of the filler pack. One of the first plurality of ceramic composite plies or the second plurality of ceramic composite plies includes a bend angle, to define an interstice between the plurality of ceramic matrix composite plies with the filler pack disposed in the interstice. The filler pack includes one or more sacrificial fibers disposed therein, that subsequent to removal provide a functional feature, such as a cooling manifold in the filler pack. The method further includes forming one or more channels coupled to the one or more functional features for the flow of a cooling fluid therethrough. A ceramic matrix composite is also disclosed.

A method of forming a composite component is provided. The method includes locating a fibrous preform, providing a slurry, mixing the slurry with sacrificial fibers, injecting the slurry into the fibrous preform, heating the fibrous preform, forming channels in the fibrous preform, and densifying the fibrous preform. The sacrificial fibers are suspended in the fibrous preform along an injection pathway such that heating the sacrificial fibers forms the channels along the injection pathway as the sacrificial fibers are burned away.

A batch composition containing pre-reacted inorganic spheroidal particles and pore-former spheroidal particles. The pre-reacted inorganic spheroidal particles have a particle size distribution wherein 10 μm≤DI.sub.50≤50 μm, and DIb≤2.0, and the pore-former spheroidal particles have a particle size distribution wherein 0.40 DI.sub.50≤DP.sub.50≤0.90 DI.sub.50, and DPb≤1.32, wherein DI.sub.50 is a median particle diameter of the distribution of pre-reacted inorganic spheroidal particles, DP.sub.50 is a median particle diameter of the pore-former particle size distribution, DIb is a breadth factor of the pre-reacted particle size distribution of the pre-reacted inorganic spheroidal particles, and DPb is a breadth factor of the pore-former particle size distribution. Also, green honeycomb bodies manufactured from the batch compositions, and methods of manufacturing a honeycomb body using the batch compositions, are provided.