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.

A method of forming a ceramic matrix composite component with cooling channels includes embedding a plurality of wires into a preform structure, densifying the preform structure with embedded wires, and removing the plurality of wires to create a plurality of corresponding channels within the densified structure.

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.

The present invention discloses novel methods for producing highly porous ceramic and/or metal aerogel monolithic objects that are hard, sturdy, and resistant to high temperatures. These methods comprise preparing nanoparticulate oxides of metals and/or metalloids via a step of vigorous stirring to prevent gelation, preparing polymer-modified xerogel powder compositions by reacting said nanoparticulate oxides with one or more polyfunctional monomers, compressing said polymer-modified xerogel powder compositions into shaped compacts, and carbothermal conversion of the shaped xerogel compacts via pyrolysis to provide the highly porous ceramic and/or metal aerogel monolithic objects that have the same shapes as to their corresponding xerogel compact precursors. Representative of the highly porous ceramic and/or metal aerogel monolithic objects of the invention are ceramic and/or metal aerogels of Si, Zr, Hf, Ti, Cr, Fe, Co, Ni, Cu, Ru, Au, and the like. Examples include sturdy, shaped, highly porous silicon carbide (SiC), silicon nitride (Si.sub.3N.sub.4), zirconium carbide (ZrC), hafnium carbide (HfC), chromium carbide (Cr.sub.3C.sub.2), titanium carbide (TiC), zirconium boride (ZrB.sub.2), hafnium boride (HfB.sub.2), and metallic aerogels of iron (Fe), nickel (Ni), cobalt (Co), copper (Cu), ruthenium (Ru), gold (Au), and the like. Said aerogel monolithic objects have utility in various applications such as, illustratively, in abrasives, in cutting tools, as catalyst support materials such as in reformers and converters, as filters such as for molten metals and hot gasses, in bio-medical tissue engineering such as bone replacement materials, in applications requiring strong lightweight materials such as in automotive and aircraft structural components, in ultra-high temperature ceramics, and the like.

Coating systems are provided for positioning on a surface of a substrate, along with the resulting coated components and methods of their formation. The coating system may include a layer having a compound of the formula: A.sub.1bB.sub.bZ.sub.1dD.sub.dMO.sub.6 where: A is Al, Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof; b is 0 to about 0.5; Z is Hf, Ti, or a mixture thereof; D is Zr, Ce, Ge, Si, or a mixture thereof; d is 0 to about 0.5; and M is Ta, Nb, or a mixture thereof.

Methods for producing oxide/metal composite components for use in high temperature systems, and components produced thereby. The methods use a fluid reactant and a porous preform that contains a solid oxide reactant. The fluid reactant contains yttrium as a displacing metal and the solid oxide reactant of the preform contains niobium oxide, of which niobium cations are displaceable species. The preform is infiltrated with the fluid reactant to react its yttrium with the niobium oxide of the solid oxide reactant and produce an yttria/niobium composite component, during which yttrium at least partially replaces the niobium cations of the solid oxide reactant to produce yttria and niobium metal, which together define a reaction product. The pore volume of the preform is at least partially filled by the reaction product, whose volume is greater than the volume lost by the solid oxide reactant as a result of reacting yttrium and niobium oxide.

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 oxidation protection system disposed on a substrate is provided, which may comprise a boron layer comprising a boron compound disposed on the substrate; a silicon layer comprising a silicon compound disposed on the boron layer; and at least one sealing layer comprising monoaluminum phosphate and phosphoric acid disposed on the silicon layer.

This disclosure provides a method of pressure sintering an environmental barrier coating on a surface of a ceramic substrate to form an article. The method 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.

The present disclosure provides a method for coating a composite structure, comprising applying a single pretreating composition on a surface of the composite structure, the single pretreating composition comprising a first acid aluminum phosphate comprising a molar ratio of aluminum to phosphate between 1 to 2 and 1 to 3, and heating the composite structure to a first temperature sufficient to form an aluminum phosphate polymer layer on the composite structure.