A method for forming a ceramic matrix composite component includes forming a fibrous preform of the component with a plurality of fiber layers and a fill region disposed between one or more of the plurality of fiber layers. Ceramic particles are provided in the fill region, which is densified using chemical vapor infiltration.

The present invention provides A magnesium oxide whisker in-situ formed MA spinel-reinforced magnesium oxide-based ceramic foam filter and a method for preparing the same. The method comprising: 1) preparing a ceramic slurry having a solid content of 60%-70% by dosing 15%-25% by mass of a nanometer alumina sol, 0.8%-1.5% by mass of a rheological agent, and the balance magnesium oxide ceramic powder comprising magnesium oxide whiskers, and then adding deionized water and ball milling to mix until uniform, and then vacuum degassing the mixture; 2) soaking a polyurethane foam template into the ceramic slurry, squeezing by a roller press the polyurethane foam template to remove redundant slurry therein to make a biscuit, and drying the biscuit by heating it to 80° C.-1200° C.; 3) putting the dried biscuit into a sintering furnace, elevating the temperature to 1400° C.-1600° C. and performing a high temperature sintering, cooling to the room temperature with the furnace to obtain the magnesium oxide-based ceramic foam filter.

Systems, devices, and methods are provided for manufacturing a carbon ceramic brake disc. Generally, a plurality of uncured or partially-cured bulk molding compound preforms or molding compound layers and ventilation cores are placed in a mold cavity and warm-pressed at a first temperature. The ventilation cores are removed from the resulting cured green body. The cured green body is then removed from the mold, and treated through a polymer infiltration and pyrolysis or reactive melt infiltration process. Certain steps can be repeated until a desired target density or weight is attained.

A silicon carbide flow reactor fluidic module comprises a monolithic closed-porosity silicon carbide body, a tortuous fluid passage extending through the silicon carbide body, the tortuous fluid passage having an interior surface, and one or more thermal control fluid passages also extending through the silicon carbide body, the interior surface having a surface roughness of less than 10 μm Ra. A process for forming such modules is also disclosed.

A method for constructing multiple ceramic layers by winding continuous ceramic filaments of identical composition to prepare multilayer RF-transparent structures is provided. In the method, identical continuous ceramic filaments are wound to construct a layer with specific dielectric constant according to patterns, characterized by the winding angle, winding density/inter-fiber aperture and winding count/layer thickness. Layers with same or different dielectric characteristics forms a sandwich design to fulfill the desired mechanical, thermal and electrical requirements.

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.

An MA-M.sub.2T spinel solid solution-reinforced magnesium oxide-based ceramic foam filter and a preparation therefor. The preparation method comprising: 1) preparing a ceramic slurry having a solid content of 60%-70% by dosing 15%-25% by mass of a nanometer alumina sol, 0.8%-1.5% by mass of a rheological agent, and the balance magnesium oxide ceramic powder comprising a nanometer titanium oxide sintering aid, and then adding deionized water and ball milling to mix until uniform, and then vacuum degassing the mixture; 2) soaking a polyurethane foam plastic template into the ceramic slurry, squeezing by a roller press the polyurethane foam plastic template to remove redundant slurry therein to make a biscuit, and drying the biscuit by heating it to 80° C.-120° C.; 3) putting the dried biscuit into a sintering furnace, elevating the temperature to 1400° C.-1600° C. and performing a high temperature sintering, cooling to the room temperature with the furnace to obtain the magnesium oxide-based ceramic foam filter.

A system for forming a product with different size particles is disclosed. The system comprises at least one print head region configured to retain a first group of print heads configurable to additively print at least a first portion of the product with a first material and a second group of print heads configurable to additively print at least a second portion of the product with a second material. The described system may also comprise a processor configured to regulate the first group of print heads and the second group of print heads to distribute the first material and the second material. A method of making an object by ink jet printing using the disclosed system is also disclosed.

A method of forming a cast component and a method of forming a casting mold is described herein. The ceramic core-shell mold includes at least first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

A seal includes a ceramic matrix composite ply having woven ceramic-based fibers in a ceramic-based matrix. The ceramic matrix composite ply has at least one bend formed about a bend axis and defines at least one rounded portion. A sealed assembly and a method of making a seal are also disclosed.