A process for manufacturing an abradable layer, includes compressing a powder composition including at least micrometric ceramic particles having a number-average form factor greater than or equal to 3, a mass content of said micrometric ceramic particles in the powder composition being greater than or equal to 85%, the form factor of a particle being defined as the ratio [largest dimension of the particle]/[largest cross-sectional dimension of the particle], and sintering the powder composition thus compressed to obtain the abradable layer, wherein a temperature imposed during sintering, the sintering time and the compression pressure applied are selected so as to obtain a volume porosity rate of the abradable layer greater than or equal to 20%.

An oxidation protection system disposed on a substrate is provided, which may comprise a base layer comprising a first pre-slurry composition comprising a first phosphate glass composition, and/or a sealing layer comprising a second pre-slurry composition comprising a second phosphate glass composition and a strengthening compound comprising boron nitride, a metal oxide, and/or silicon carbide.

The present disclosure provides a method for coating a composite structure, comprising forming a first slurry by combining a first pre-slurry composition comprising a first phosphate glass composition, with a primary flow modifier and a first carrier fluid, wherein the primary flow modifier comprises at least one of cellulose or calcium silicate; applying the first slurry on a surface of the composite structure to form a base layer; and heating the composite structure to a temperature sufficient to adhere the base layer to the composite structure.

A method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate to form an article includes the steps of etching the surface of the ceramic substrate to texture the surface, disposing an environmental barrier coating on the etched surface of the ceramic substrate wherein the environmental barrier coating includes a rare earth silicate, and pressure sintering the environmental barrier coating on the etched surface of the ceramic substrate in an inert or nitrogen atmosphere at a pressure of greater than atmospheric pressure such that at least a portion of the environmental barrier coating is disposed in the texture of the surface of the ceramic substrate thereby forming the article.

CMC components having microchannels and methods for forming microchannels in CMC components are provided. For example, a method for forming microchannels in a CMC component comprises laying up a plurality of body plies for forming a body of the CMC component; laying up a microchannel ply on the plurality of body plies that has at least one void therein for forming at least one microchannel; laying up a cover ply on the microchannel ply to define an outer layer of the CMC component; and processing the laid up body plies, microchannel ply, and cover ply to form the CMC component. In another embodiment, the method comprises applying an additive matrix to the body plies to define at least one microchannel. In still other embodiments, the method comprises machining at least one microchannel in the plurality of body plies.

An oxidation protection system disposed on a substrate is provided, which may comprise a base layer comprising a first pre-slurry composition comprising a first phosphate glass composition, and/or a sealing layer comprising a second pre-slurry composition comprising a second phosphate glass composition and a strengthening compound comprising boron nitride, a metal oxide, and/or silicon carbide.

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 includes forming a ceramic member that has a plurality of closed pores within a ceramic matrix. The forming includes compacting a ceramic powder to form intra-particle pores between particles of the ceramic powder, and sintering the compacted ceramic powder to cause diffusion of the ceramic powder and formation of the ceramic matrix. The diffusion does not fill the intra-particle pores and leaves the closed pores.

An ink formulation for additive manufacturing of low density syntactic foams is described. The ink formulation can include a thermoset resin, a curing agent suitable for use with the thermoset resin, a plurality of hollow spheres, such as glass microballoons, one or more solvents, and one or more non-hollow, viscosity modifying filler. Also described are a method of preparing the ink formulation, a method of preparing three-dimensional objects comprising low density syntactic foams, and the three-dimensional objects prepared thereby.

A method of constructing a space construction has a preparing step, a first mixing step, a second mixing step, a matrix layer building step, a three-dimensional fiber webs paving step, and a gamma ray screening layer building step. Prepare an agitator, a strengthening material, a composite material, multiple three-dimensional fiber webs, and multiple gamma ray screening elements. Mix the strengthening material and the composite material to form a first building material. Mix the multiple gamma ray screening elements and soil on a planet to form a second building material. Build at least one matrix layer with the first building material. Pave two three-dimensional fiber webs on the at least one matrix layer. Build at least one gamma ray screening layer adjacent to one of the two three-dimensional fiber webs with the second building material. A product constructed by the method is also provided.