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1
US10399911B2
Publication/Patent Number: US10399911B2
Publication date: 2019-09-03
Application number: 15/005,790
Filing date: 2016-01-25
Abstract: The disclosure describes techniques for forming a surface layer of an article including a CMC using a cast. In some examples, the surface layer includes three-dimensional surface features, which may increase adhesion between the CMC and a coating on the CMC. In some examples, the surface layer may include excess material, with or without three-dimensional surface features, which is on the CMC. The excess material may be machined to remove some of the excess material and facilitate conforming the article to dimensional tolerances, e.g., for fitting the article to another component. The excess material may reduce a likelihood that the CMC (e.g., reinforcement material in the CMC) is damaged by the machining. The disclosure describes techniques for forming a surface layer of an article including a CMC using a cast. In some examples, the surface layer includes three-dimensional surface features, which may increase adhesion between the CMC and a coating on the CMC. In some examples ...more ...less
2
US10384980B2
Publication/Patent Number: US10384980B2
Publication date: 2019-08-20
Application number: 15/657,832
Filing date: 2017-07-24
Abstract: A method for forming in situ a boron nitride reaction product locally on a reinforcement phase of a ceramic matrix composite material includes the steps of providing a ceramic matrix composite material having a fiber reinforcement material; and forming in situ a layer of boron nitride on the fiber reinforcement material. A method for forming in situ a boron nitride reaction product locally on a reinforcement phase of a ceramic matrix composite material includes the steps of providing a ceramic matrix composite material having a fiber reinforcement material; and forming in situ a layer of boron ...more ...less
3
US10267579B2
Publication/Patent Number: US10267579B2
Publication date: 2019-04-23
Application number: 14/910,714
Filing date: 2014-05-26
Abstract: A method for improving thermal efficiency of a heating device that reduces an amount of heat flowing out from a heating device 11 to the outside by installing a heat-resistant inorganic conjugated molded product 16 in and along a pathway 15 for heated gas generated from the heating device 11 without interrupting the flow of heated gas passing the pathway 15, heating the inorganic conjugated molded product 16 with the heated gas, and putting radiation heat from the heated inorganic conjugated molded product 16 back into the heating device 11, the inorganic conjugated molded product 16 being provided with an interior layer and an exterior layer, the exterior layer consisting of a coverture for inorganic materials that protects the interior layer from heated gas. A method for improving thermal efficiency of a heating device that reduces an amount of heat flowing out from a heating device 11 to the outside by installing a heat-resistant inorganic conjugated molded product 16 in and along a pathway 15 for heated gas generated from the ...more ...less
4
US10221104B2
Publication/Patent Number: US10221104B2
Publication date: 2019-03-05
Application number: 15/165,676
Filing date: 2016-05-26
Abstract: A mixed gas containing a precursor gas, an additive gas and a carrier gas is supplied to a preform stored in an electric furnace, and silicon carbide is deposited by chemical vapor deposition or chemical vapor phase impregnation to form a film. The preform includes multiple fiber bundles, and the fiber bundles include multiple fibers. This heat-resistant composite material includes a ceramic fiber preform impregnated with silicon carbide, and producing the composite material involves a step in which silicon carbide is deposited between the fibers to integrate the fibers which configure the fiber bundles, and a step in which silicon carbide is deposited between the fiber bundles to integrate the fiber bundles. Hereby, uniformity of embedding and growth rate of the silicon carbide film are both attained. A mixed gas containing a precursor gas, an additive gas and a carrier gas is supplied to a preform stored in an electric furnace, and silicon carbide is deposited by chemical vapor deposition or chemical vapor phase impregnation to form a film. The preform includes multiple ...more ...less
5
US10253832B2
Publication/Patent Number: US10253832B2
Publication date: 2019-04-09
Application number: 14/877,701
Filing date: 2015-10-07
Abstract: Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided. Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material ...more ...less
6
US10294166B2
Publication/Patent Number: US10294166B2
Publication date: 2019-05-21
Application number: 15/022,615
Filing date: 2014-09-12
Abstract: A method of densifying a CMC article includes the steps of pyrolyzing a CMC article until a desired initial porosity is achieved, coating CMC pores within the CMC article with carbon, pyrolyzing the carbon to form carbon pores, coating the carbon pores with silicon, and heat treating the CMC article to create a silicon carbide filled pore integrated with silicon carbide of the CMC article to densify the CMC article. A method of densifying a CMC article includes the steps of pyrolyzing a CMC article until a desired initial porosity is achieved, coating CMC pores within the CMC article with carbon, pyrolyzing the carbon to form carbon pores, coating the carbon pores with silicon, and heat ...more ...less
7
US10233376B2
Publication/Patent Number: US10233376B2
Publication date: 2019-03-19
Application number: 15/273,843
Filing date: 2016-09-23
Inventor: Zhao, Lei   Xu, Zhiyue  
Abstract: A carbon composite is disclosed, including a plurality of carbon grains, wherein each of the plurality of carbon grains includes a plurality of pores, and a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a disintegrable binder. A carbon composite is disclosed, including a plurality of carbon grains, wherein each of the plurality of carbon grains includes a plurality of pores, and a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a ...more ...less
8
US10323167B2
Publication/Patent Number: US10323167B2
Publication date: 2019-06-18
Application number: 15/267,198
Filing date: 2016-09-16
Abstract: A method for fabricating a ceramic material includes impregnating a porous structure with a mixture that includes a preceramic polymer and a filler. The filler includes at least one free metal. The preceramic polymer material is then rigidized to form a green body. The green body is then thermally treated to convert the rigidized preceramic polymer material into a ceramic matrix located within pores of the porous structure. The same thermal treatment or a second, further thermal treatment is used to cause the at least one free metal to move to internal porosity defined by the ceramic matrix or pores of the porous structure. A method for fabricating a ceramic material includes impregnating a porous structure with a mixture that includes a preceramic polymer and a filler. The filler includes at least one free metal. The preceramic polymer material is then rigidized to form a green body. The green ...more ...less
9
US10323168B2
Publication/Patent Number: US10323168B2
Publication date: 2019-06-18
Application number: 15/555,532
Filing date: 2016-03-04
Abstract: A production process for a crystal oriented ceramics includes: a first step of preparing composite particles formed of particles having magnetic anisotropy having magnetic susceptibility anisotropy and seed particles having magnetic susceptibility anisotropy less than or equal to 1/10 of the magnetic susceptibility anisotropy of the particles having magnetic anisotropy and are formed of an inorganic compound having an anisotropic shape in which a crystal axis intended to be corresponds to a minor axis or a major axis; a second step of adding raw material powder including the composite particles to a solvent to prepare a slurry a third step of preparing a green compact by disposing the slurry in a static magnetic field of ≥0.1 tesla and drying the slurry in a state in which crystal axes of the seed particles in a major axis direction are in one direction; and a fourth step of sintering the green compact. A production process for a crystal oriented ceramics includes: a first step of preparing composite particles formed of particles having magnetic anisotropy having magnetic susceptibility anisotropy and seed particles having magnetic susceptibility anisotropy less than or equal ...more ...less
10
US10322974B2
Publication/Patent Number: US10322974B2
Publication date: 2019-06-18
Application number: 15/924,141
Filing date: 2018-03-16
Abstract: Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC. Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and ...more ...less
11
US10370301B2
Publication/Patent Number: US10370301B2
Publication date: 2019-08-06
Application number: 14/210,928
Filing date: 2014-03-14
Abstract: A ceramic matrix composite having improved operating characteristics includes a barrier layer.
12
US2019152861A1
Publication/Patent Number: US2019152861A1
Publication date: 2019-05-23
Application number: 16/099,922
Filing date: 2017-05-11
Abstract: A part made of composite material includes fiber reinforcement including silicon carbide fibers presenting an oxygen content less than or equal to 1% in atomic percentage; and a matrix present in the pores of the fiber reinforcement and including at least one sintered silicate phase including at least one rare earth silicate, mullite, or a mixture of mullite and of at least one rare earth silicate, the matrix including at least a first phase including mullite and a second phase, different from the first phase, including at least one rare earth silicate. A part made of composite material includes fiber reinforcement including silicon carbide fibers presenting an oxygen content less than or equal to 1% in atomic percentage; and a matrix present in the pores of the fiber reinforcement and including at least one sintered silicate ...more ...less
13
US2019152868A1
Publication/Patent Number: US2019152868A1
Publication date: 2019-05-23
Application number: 16/257,187
Filing date: 2019-01-25
Abstract: A thermally-insulating composite material with co-shrinkage in the form of an insulating material formed by the inclusion of microballoons in a matrix material such that the microballoons and the matrix material exhibit co-shrinkage upon processing. The thermally-insulating composite material can be formed by a variety of microballoon-matrix material combinations such as polymer microballoons in a preceramic matrix material. The matrix materials generally contain fine rigid fillers. A thermally-insulating composite material with co-shrinkage in the form of an insulating material formed by the inclusion of microballoons in a matrix material such that the microballoons and the matrix material exhibit co-shrinkage upon processing. The thermally-insulating ...more ...less
14
US2019162263A1
Publication/Patent Number: US2019162263A1
Publication date: 2019-05-30
Application number: 16/262,576
Filing date: 2019-01-30
Abstract: Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided. Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material ...more ...less
15
US2019084892A1
Publication/Patent Number: US2019084892A1
Publication date: 2019-03-21
Application number: 15/710,954
Filing date: 2017-09-21
Abstract: A ceramic matrix composite article includes a chemical vapor infiltration ceramic matrix composite base portion including ceramic fiber reinforcement material in a ceramic matrix material having between 0% and 5% free silicon. The ceramic matrix composite article further includes a melt infiltration ceramic matrix composite covering portion including a ceramic fiber reinforcement material in a ceramic matrix material having a greater percentage of free silicon than the chemical vapor infiltration ceramic matrix composite base portion. A ceramic matrix composite article includes a chemical vapor infiltration ceramic matrix composite base portion including ceramic fiber reinforcement material in a ceramic matrix material having between 0% and 5% free silicon. The ceramic matrix composite article further ...more ...less
16
US2019210929A1
Publication/Patent Number: US2019210929A1
Publication date: 2019-07-11
Application number: 15/863,160
Filing date: 2018-01-05
Abstract: A method for forming a hole within a ceramic matrix composite component includes forming a first core portion for a ceramic matrix composite component; embedding a hollow member into the first core portion at a desired location; wrapping the first core portion with a first ceramic matrix composite material; inserting a rod through the hollow member and into the first core portion; removing the hollow member; assembling a second core portion to the first core portion such that the rod extends into the second core portion; and wrapping the first core portion and the second core portion with a second ceramic matrix composite material. A method for forming a hole within a ceramic matrix composite component includes forming a first core portion for a ceramic matrix composite component; embedding a hollow member into the first core portion at a desired location; wrapping the first core portion with a first ...more ...less
17
US2019249059A1
Publication/Patent Number: US2019249059A1
Publication date: 2019-08-15
Application number: 16/309,132
Filing date: 2017-06-12
Abstract: Provided is a method for producing a novel silicon carbide that can be reacted at a low reaction temperature. The present invention pertains to a silicon carbide production method comprising a step for sintering a composition that at least contains: silicon nanoparticles having an average particle diameter of less than 200 nm; and a carbon-based material. Provided is a method for producing a novel silicon carbide that can be reacted at a low reaction temperature. The present invention pertains to a silicon carbide production method comprising a step for sintering a composition that at least contains: silicon nanoparticles having ...more ...less
18
US2019010091A1
Publication/Patent Number: US2019010091A1
Publication date: 2019-01-10
Application number: 16/129,845
Filing date: 2018-09-13
Abstract: A three-dimensional (3D) printing composition includes ceramic filaments comprising an additive having an aspect ratio of at least 2:1. 3D printed ceramic articles include the ceramic filaments.