A method of forming a ceramic matrix composite component having an internal cooling circuit includes wrapping at least a first sheet around a first mandrel, wrapping at least a second sheet around a second mandrel, creating a first plurality of holes in the first sheet corresponding to a plurality of openings in the first mandrel, creating a second plurality of holes in the second sheet corresponding to a plurality of openings in the second mandrel, aligning the first mandrel and the second mandrel such that the first plurality of holes face and are aligned with the second plurality of holes, wrapping at least a third sheet around both the first mandrel and second mandrel to form a preform, the preform comprising each of the first sheet, the second sheet, and the third sheet, and densifying the preform. The first sheet, second sheet, and third sheet are formed from a ceramic fiber material.

A method of forming a ceramic matrix composite component having an internal cooling circuit includes wrapping at least a first sheet around a first mandrel, wrapping at least a second sheet around a second mandrel, creating a first plurality of holes in the first sheet corresponding to a plurality of openings in the first mandrel, creating a second plurality of holes in the second sheet corresponding to a plurality of openings in the second mandrel, aligning the first mandrel and the second mandrel such that the first plurality of holes face and are aligned with the second plurality of holes, wrapping at least a third sheet around both the first mandrel and second mandrel to form a preform, the preform comprising each of the first sheet, the second sheet, and the third sheet, and densifying the preform. The first sheet, second sheet, and third sheet are formed from a ceramic fiber material.

A method of forming a ceramic matrix composite component having an internal cooling circuit includes wrapping at least a first sheet around a first mandrel, wrapping at least a second sheet around a second mandrel, creating a first plurality of holes in the first sheet corresponding to a plurality of openings in the first mandrel, creating a second plurality of holes in the second sheet corresponding to a plurality of openings in the second mandrel, aligning the first mandrel and the second mandrel such that the first plurality of holes face and are aligned with the second plurality of holes, wrapping at least a third sheet around both the first mandrel and second mandrel to form a preform, the preform comprising each of the first sheet, the second sheet, and the third sheet, and densifying the preform. The first sheet, second sheet, and third sheet are formed from a ceramic fiber material.

A method of forming a ceramic matrix composite component having an internal cooling circuit includes wrapping at least a first sheet around a first mandrel, wrapping at least a second sheet around a second mandrel, creating a first plurality of holes in the first sheet corresponding to a plurality of openings in the first mandrel, creating a second plurality of holes in the second sheet corresponding to a plurality of openings in the second mandrel, aligning the first mandrel and the second mandrel such that the first plurality of holes face and are aligned with the second plurality of holes, wrapping at least a third sheet around both the first mandrel and second mandrel to form a preform, the preform comprising each of the first sheet, the second sheet, and the third sheet, and densifying the preform. The first sheet, second sheet, and third sheet are formed from a ceramic fiber material.

A method of preparing a ceramic fabric for use in a ceramic matrix composite includes transforming a ceramic tow from a first tow geometry to a second tow geometry, thereby reducing a first dimension of the ceramic tow and increasing a second dimension of the ceramic tow orthogonal to the first dimension to produce a flattened tow. The method includes weaving or braiding the flattened ceramic tow to form a ceramic fabric.

A method of preparing a ceramic fabric for use in a ceramic matrix composite includes transforming a ceramic tow from a first tow geometry to a second tow geometry, thereby reducing a first dimension of the ceramic tow and increasing a second dimension of the ceramic tow orthogonal to the first dimension to produce a flattened tow. The method includes weaving or braiding the flattened ceramic tow to form a ceramic fabric.

An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).

An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).

The present invention relates to a layered formed sheet comprising two or more formed sheets each formed from a curable composition comprising (A) an aluminosilicate source, (B) an alkaline metal hydroxide, (C) cellulose-based fibers and (D) alkali-resistant fibers other than cellulose-based fibers, in which the aluminosilicate source (A) comprises a blast furnace slag, and the content of a blast furnace slag having a specific surface area of 1000 cm.sup.2/g or more and 9000 cm.sup.2/g or less is more than 55% by mass and 90% by mass or less related to a total solid content in the curable composition.

The present invention relates to a layered formed sheet comprising two or more formed sheets each formed from a curable composition comprising (A) an aluminosilicate source, (B) an alkaline metal hydroxide, (C) cellulose-based fibers and (D) alkali-resistant fibers other than cellulose-based fibers, in which the aluminosilicate source (A) comprises a blast furnace slag, and the content of a blast furnace slag having a specific surface area of 1000 cm.sup.2/g or more and 9000 cm.sup.2/g or less is more than 55% by mass and 90% by mass or less related to a total solid content in the curable composition.