A thermostructural composite material part including carbon or ceramic fiber reinforcement densified by a matrix having at least one thin portion in which: the thickness of the part is less than 2 mm, or indeed less than 1 mm; the fiber reinforcement is made as a single thickness of multilayer fabric made of spread yarns having a weight of not less than 200 tex; the fiber volume ratio lies in the range 25% to 45%; and the ratio between the number of layers of the multilayer fabric and the thickness in millimeters of the part is not less than four.

Single-airfoil vanes each having an inner platform, an outer platform, and an airfoil are obtained by three-dimensionally weaving a fiber blank in a single piece, by shaping the fiber blank to obtain a single-piece fiber preform, and by densifying the preform with a matrix to obtain a vane of composite material forming a single piece with inner and outer platforms incorporated therein. A plurality of vanes is assembled together at an intermediate stage of densification to form a multi-airfoil composite material guide vane sector for a turbine nozzle or a compressor diffuser and the assembled-together vanes are bonded together.

The present disclosure relates to a method of fabricating a ceramic composite components. The method may include providing at least a first layer of reinforcing fiber material which may be a pre-impregnated fiber. An additively manufactured component may be provided on or near the first layer. A second layer of reinforcing fiber, which may be a pre-impregnated fiber may be formed on top the additively manufactured component. A precursor is densified to consolidates at least the first and second layer into a densified composite, wherein the additively manufactured material defines at least one cooling passage in the densified composite component.

Ceramic matrix composite articles include, for example, a plurality of unidirectional arrays of fiber tows in a matrix having a monomodal pore size distribution, and a fiber volume fraction between about 15 percent and about 35 percent. The articles may be formed by, for example, providing a shaped preform comprising a prepreg tape layup of unidirectional arrays of fiber tows, a matrix precursor, and a pore former, curing the shaped preform to pyrolyze the matrix precursor and burnout the pore former so that the shaped preform comprises the unidirectional arrays of fiber tows and a porous matrix having a monomodal pore size distribution, and subjecting the cured shaped preform to chemical vapor infiltration to densify the porous matrix so that the ceramic matrix composite article has a fiber volume fraction between about 15 percent and about 35 percent.

A carbon-carbon composite preform including a plurality of layers including carbon fibers or carbon-precursor fibers, the layers include a first exterior layer defining a first major surface, a second exterior layer defining a second major surface, and at least one interior layer disposed between the first exterior layer and the second exterior layer, the at least one interior layer having a peripheral region that forms a portion of an outer surface of the preform. The preform includes needled fibers, where at least some needled fibers extend through two or more layers. The preform has an exterior region and a core region, where the exterior region includes at least the peripheral region of at least one interior layer. The needled fibers define a first needled fiber number density (NFND) in the exterior region and a second greater NFND in at least a portion of the core region.

Process for the production of a hydrophobic thermal-insulation moulding, where a hydrophilic thermal-insulation moulding is brought into contact with a hydrophobizing agent in vapour form with formation of a thermal-insulation moulding coated with hydrophobizing agent, and this is then subjected to a press process and during the press process and/or after the press process is reacted with the hydrophobizing agent with formation of the hydrophobic thermal-insulation moulding, where a) the density of the hydrophobic thermal-insulation moulding after the press process and after the reaction with the hydrophobizing agent is from 100 to 250 kg/m.sup.3, and b) the density of the hydrophilic thermal-insulation moulding on contact with the hydrophobizing agent is from 50% to less than 100% of the density of the hydrophobic thermal-insulation moulding.

A method for manufacturing a part from a first ceramic or from carbon, consolidated by a second ceramic, having a determined geometry, that involves carrying out the following sequence of steps: a) manufacturing a preform made from an organic polymer; b) impregnating the preform made from an organic polymer with a resin that is a precursor of the first ceramic or a resin that is a precursor of carbon; c) crosslinking and/or polymerising, then pyrolysing the resin that is a precursor of the first ceramic or the resin that is a precursor of carbon; to obtain a part made from a first ceramic or from carbon having the same geometry as the part to be manufactured; e) depositing the second ceramic on the part made from a first ceramic or from carbon by means of a chemical vapour deposition or CVD process or a chemical vapour infiltration or CVI process.

A novel ceramic matrix composite is disclosed for forming components that are operable in high temperature environments such those in gas turbine engines and the like. The ceramic matrix composite can include at least one layer of non-crimped fibers positioned substantially parallel to one another. A relatively small diameter elastic fiber can be constructed to stitch the non-crimped fibers together and a ceramic matrix may be deposited around the at least one layer of non-crimped fibers.

A fibrous preform (1) is produced, provided with a sandwich structure comprising an intermediate flexible core (4) and two outer fibrous frames (2, 3), respectively arranged on opposing outer faces of said flexible core (4) and assembled by sections of wire (8, 9) passing through said fibrous frames (2, 3), said preform (1) being impregnated with resin. Said preform is then hardened and the core (4) is removed, preferably by pre-densification with chemical vapour infiltration, and the structure produced is then densified with liquid-phase infiltration.

A production method for a ceramic matrix composite is comprised of: compounding an aggregate powder including a ceramic and a binder including at least one of thermoplastic resins and waxes to form a composition of the aggregate powder and the binder; pressing the composition to form sheets; accumulating fabrics of reinforcement fibers including the ceramic and the sheets alternately; pressing an accumulated body of the fabrics and the sheets; and generating a matrix combining the reinforcement fibers together.