A ceramic bonding material including at least one fibrous material, a flux agent and a thickening agent wherein the ceramic bonding material fired at a set temperature to bond the two adjacent substrate faces.

A method for injecting a loaded suspension into a fibrous texture having a three-dimensional or multilayer weaving includes the injection of a suspension containing a powder of solid particles into the volume of the fibrous texture. The injection of the loaded suspension is carried out by at least one hollow needle in communication with a loaded suspension supply device, each needle being movable in at least one direction extending between a first face and a second opposite face of the fibrous texture so as to inject the loaded suspension at one or more determined depths in the fibrous texture.

A continuous operation method is employed for the microwave high-temperature pyrolysis of a solid material containing an organic matter. The method includes the steps of mixing a solid material containing an organic matter with a liquid organic medium; transferring the obtained mixture to a microwave field; and in the microwave field, continuously contacting the mixture with a strong wave absorption material in an inert atmosphere or in vacuum. The strong wave absorption material continuously generates a high temperature under a microwave such that the solid material containing an organic matter and the liquid organic medium are continuously pyrolyzed to implement a continuous operation.

A composite material consisting of a matrix made of at least one aluminosilicate notably selected from barium aluminosilicate BAS, barium and strontium aluminosilicate BSAS, strontium aluminosilicate SAS, and mixtures thereof, reinforced by reinforcements made of at least one metal or metalloid oxide, the expansion coefficient of which is close to that of said at least one aluminosilicate.

A method for preparing said composite material.

A composite material according to the invention notably finding its application in the aeronautical or aerospace field, for example for the manufacture of radomes.

Disclosed herein is a ceramic matrix composite airfoil comprising a triple bifurcated ply that defines a suction side, an outer platform, a pressure side and an inner platform of the airfoil, wherein the triple bifurcated ply comprises at least one ply that comprises a consolidated region, wherein the consolidated region is split into two bifurcated regions in three locations in three different directions.

A method for infiltrating a porous preform for a gas turbine engine is provided, which comprises providing a chamber for infiltrating a porous preform. The porous preform is positioned within a slurry confinement fixture within the chamber. A vacuum is created in the chamber. A solvent is added to the slurry confinement fixture until a pressure in the chamber is substantially equal to an equilibrium partial pressure of the solvent. A slurry is added to the slurry confinement fixture. The slurry includes the solvent and a particulate. The pressure in the chamber is increased, and the slurry is urged into the porous preform.

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing”). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

A manufacturing method for a composite material part includes injecting under pressure a slip containing a refractory ceramic particle powder into the moulding cavity of an injection tooling, draining the liquid from the slip that passed through the moulding cavity and retaining the particle powder inside the moulding cavity to obtain a blank including refractory particles, demoulding the blank, and heat treating the blank to form a part. The injection tooling includes a porous material mould consisting of a moulding cavity, an enclosure of rigid material in which the porous material mould is held, the enclosure further including an injection port, a discharge vent and an injection canal connecting the injection port to the moulding cavity of the porous mould for the injection of the slip into the moulding cavity. The injection tooling includes a sacrificial capsule of porous material placed in moulding cavity.

The present invention relates to surface-treated prepreg composites and corresponding methods of surface treating an inorganic fabric to form a surface-treated fabric reinforced prepreg composite. The method comprises infiltrating an inorganic fabric with a first slurry mixture to form an infiltrated fabric; optionally drying the infiltrated fabric; infiltrating an inorganic paper with a second slurry mixture to form an infiltrated paper; optionally drying the infiltrated paper; and applying the infiltrated paper to at least one surface of the infiltrated fabric to form a surface-treated prepreg composite.