Abstract:
The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the composite body such that any undesirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. The getterer material(s) may form at least one compound which acts as a passivation layer, and/or is able to move by bulk transport (e.g., by viscous flow as a glassy material) to a crack, and sealing the crack, thereby further enhancing the oxidation protection of the composite body. One or more ceramic filler materials which serve as reinforcements may have a plurality of superimposed coatings thereon, at least one of which coatings may function as or contain an oxidation protection mechanism. Specifically, a coating comprising boron nitride which has been engineered or modified to contain some silicon exhibits improved corrosion resistance, specifically to oxygen and moisture. The coated materials may be useful as reinforcing materials in high performance composites to provide improved mechanical properties such as fracture toughness. The present invention also relates to improved composites which incorporate these materials, and to their methods of manufacture.
Abstract:
Improvements in processing metal matrix composite materials by infiltration are disclosed. Specifically, a permeable mass comprising a preform or bedding material is provided to an infiltration setup in addition to that being the objective of the infiltration. The additional preform or bed is itself infiltrated at least at some point during processing to produce an additional, e.g., "sacrificial" MMC body. This sacrificial MMC reduces the amount that the carcass of matrix metal may shrink during cooling which in turn reduces the stress on and warping induced in the objective preform. The second or additional bed or preform is termed a "sacrificial" bed or sacrificial preform. The sacrificial bed or preform may be disposed between the object preform and the body of matrix metal, or opposite the body of matrix metal from the object preform, or both. The sacrificial MMC may be reused in subsequent infiltration setups to produce additional infiltrations of objective preforms. Further, a separation facilitator may be disposed between the objective preform and the sacrificial bedding/preform/MMC to assist in the recovery of the desired MMC body following infiltration and solidification of matrix metal.
Abstract:
The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) of reinforcement materials in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the composite body such that any undesirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. In a preferred embodiment of the present invention, the getterer material(s) form at least one compound (e.g., at least one glassy material) which acts as a crack sealant, thereby further enhancing the oxidation protection of the composite body. One or more ceramic filler materials which serve as reinforcements may have a plurality of superimposed coatings thereon, at least one of which coatings may function as a getterer. The coated materials may be useful as reinforcing materials in ceramic matrix composites to provide improved mechanical properties such as fracture toughness. The present invention also relates to improved composites which incorporate these materials, and to their methods of manufacture.
Abstract:
Improvements in processing metal matrix composite materials by infiltration are disclosed. Specifically, a permeable mass comprising a preform or bedding material is provided to an infiltration setup in addition to that being the objective of the infiltration. The additional preform or bed is itself infiltrated at least at some point during processing to produce an additional, e.g., "sacrificial" MMC body. This sacrificial MMC reduces the amount that the carcass of matrix metal may shrink during cooling which in turn reduces the stress on and warping induced in the objective preform. The second or additional bed or preform is termed a "sacrificial" bed or sacrificial preform. The sacrificial bed or preform may be disposed between the object preform and the body of matrix metal, or opposite the body of matrix metal from the object preform, or both. The sacrificial MMC may be reused in subsequent infiltration setups to produce additional infiltrations of objective preforms. Further, a separation facilitator may be disposed between the objective preform and the sacrificial bedding/preform/MMC to assist in the recovery of the desired MMC body following infiltration and solidification of matrix metal.
Abstract:
This invention relates generally to a novel method for joining at least one first self-supporting body to at least one second self-supporting body which is similar in composition to or different in composition from said at least one first self-supporting body and to novel products which result from such joining. In some of its more specific aspects, this invention relates to different techniques for joining ceramic matrix composite bodies to other ceramic matrix composite bodies of similar characteristics and for joining ceramic matrix composite bodies to bodies which have different characteristics (e.g., metals). The ceramic matrix composite bodies of this invention are produced by a reactive infiltration of a molten parent metal into a bed or mass containing at least one of a boron source material, a carbon source material, and a nitrogen source material and, optionally, one or more inert fillers.