A method of manufacturing a ceramic matrix composite component includes pressure casting a fibrous preform with a slurry comprising boron carbide and densifying the fibrous preform using a liquid source of carbon. The method may include forming holes in the fibrous preform before pressure casting the fibrous preform with the slurry. The method may also include sintering the boron carbide after the pressure casting. In various embodiments, the sintering may be performed before the densifying.

The present disclosure includes carbon-carbon composite articles having multiphase glass oxidation protection coatings for limiting thermal and/or catalytic oxidation reactions and methods for applying multiphase glass oxidation protection coatings to carbon-carbon composite articles.

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.

Systems and methods for forming an oxidation protection system on a composite structure are provided. In various embodiments, the oxidation protection system comprises a boron-glass layer formed on the composite substrate and a silicon-glass layer formed over the boron-glass layer. Each of the boron-glass layer and the silicon-glass layer includes a glass former.

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.

A process for manufacturing a friction component made of composite material, includes the densification of a fibrous preform of carbon yarns by a matrix including at least pyrocarbon and at least one ZrO.sub.xC.sub.y phase, where 1≤x≤2 and 0≤y≤1, the matrix being formed by chemical vapor infiltration at least from a first gaseous precursor of pyrocarbon and a second gaseous precursor including zirconium, the second precursor being an alcohol or a C.sub.1 to C.sub.6 polyalcohol modified by linking the oxygen atom of at least one alcohol function to a group of formula —Zr—R.sub.3, the substituents R being identical or different, and R being selected from: —H, C.sub.1 to C.sub.5 carbon chains and halogen atoms.

A method for forming a high temperature coating includes applying carbon powder to a surface of a carbon/carbon (C/C) composite substrate to force the carbon powder into one or more surface voids of the surface of the C/C composite substrate. The carbon powder has a substantially same composition and morphology as a surface portion of the C/C composite substrate. The method includes applying a metal slurry to the surface of the C/C composite substrate following the application of the carbon powder and reacting a metal of the metal slurry with carbon of the carbon powder and carbon of the surface portion of the C/C composite substrate to form a metal-rich antioxidant layer of a metal carbide on the C/C composite substrate.

A method for densifying porous annular substrates by chemical vapor infiltration, includes providing a plurality of unit modules including a support tray on which substrates are stacked, the support tray including a gas intake opening extended by an injection tube disposed in an internal volume formed by the central passages of the stacked substrates, the injection tube including gas injection orifices opening into the internal volume, forming stacks of unit modules in the enclosure of a densification furnace and injecting, into the stacks of unit modules, a gas phase including a gas precursor of a matrix material to be deposited within the porosity of the substrates.

An example method includes combining an interlayer and a carbon fiber fabric, wherein the interlayer comprises a highly oriented milled carbon fiber ply comprising a plurality of out-of-plane carbon fibers. The method further includes winding the interlayer and the carbon fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.

An example method includes forming an interlayer on a carbon fiber fabric to form a composite fiber fabric. The interlayer comprises a binder. The method further includes winding the composite fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.