Method of densifying a ceramic matrix composite using a filled tackifier

Abstract

A method of producing an enhanced ceramic matrix composite includes applying a tackifier compound to a fiber preform. The tackifier compound includes inorganic filler particles. The method further includes modifying the tackifier compound such that the inorganic filler particles remain interspersed throughout the fiber preform, and occupy pores of fiber preform.

1 . A method of producing an enhanced ceramic matrix composite, the method comprising:
 applying a tackifier compound to a fiber preform, the tackifier compound comprising inorganic filler particles; and   modifying the tackifier compound such that the inorganic filler particles remain interspersed throughout the fiber preform and occupy pores of the fiber preform.   
     
     
         2 . The method of  claim 1  and further comprising: coating the fiber preform with an interface coating using a chemical vapor infiltration or chemical vapor deposition process. 
     
     
         3 . The method of  claim 1  and further comprising: forming a matrix surrounding the fiber preform using a chemical vapor infiltration or chemical vapor deposition process. 
     
     
         4 . The method of  claim 3  and further comprising: applying a thermal barrier coating or an environmental barrier coating to the ceramic matrix composite. 
     
     
         5 . The method of  claim 1 , wherein the tackifier compound further comprises a solvent and a resin. 
     
     
         6 . The method of  claim 5 , wherein the solvent comprises water, acetone, ethanol, isopropanol, or toluene. 
     
     
         7 . The method of  claim 5 , wherein the resin comprises polyvinyl-alcohol, polyvinyl-styrene, or polyacrylate. 
     
     
         8 . The method of  claim 5 , wherein applying the tackifier compound comprises a technique selected from the group consisting of spraying, painting, filming, dip-coating, and combinations thereof. 
     
     
         9 . The method of  claim 1 , wherein the inorganic filler particles comprise a ceramic material or a preceramic polymer. 
     
     
         10 . The method of  claim 9 , wherein the ceramic material is formed from a material selected from the group consisting of silicon carbide, silicon nitride, pure silicon, boron carbide, pure carbon, aluminum oxide, hafnia, and combinations thereof. 
     
     
         11 . The method of  claim 9 , wherein the preceramic polymer is formed from a material selected from the group consisting of polycarbosilane, polycarbosiloxane, polycarbosilazane, polycarbodiimides, and combinations thereof. 
     
     
         12 . The method of  claim 11 , wherein modifying the tackifier compound comprises a thermochemical decomposition technique or a crosslinking technique. 
     
     
         13 . An enhanced ceramic matrix composite comprising:
 a fiber preform interspersed with inorganic filler particles; and   a matrix formed over the fiber preform and the inorganic filler particles;   wherein the ceramic matrix composite has a porosity of less than 20%.   
     
     
         14 . The ceramic matrix composite of  claim 13 , wherein the inorganic filler particles comprise spherical particles, chopped fibers, and combinations thereof. 
     
     
         15 . The ceramic matric composite of  claim 13 , wherein the inorganic filler particles comprise a ceramic material. 
     
     
         16 . The ceramic matrix composite of  claim 15 , wherein the ceramic is formed from a material selected from the group consisting of silicon carbide, silicon nitride, pure silicon, boron carbide, pure carbon, aluminum oxide, hafnia, and combinations thereof. 
     
     
         17 . The ceramic matrix composite of  claim 15 , wherein the ceramic is formed from a decomposed preceramic polymer, the preceramic polymer being formed from a material selected from the group consisting of polycarbosilane, polycarbosiloxane, polycarbosilazane, polycarbodiimides, and combinations thereof. 
     
     
         18 . The ceramic matrix composite of  claim 13 , wherein the inorganic filler particles comprises spherical particles, elongated particles, and combinations thereof. 
     
     
         19 . The ceramic matrix composite of  claim 18 , wherein a diameter of the inorganic filler particles ranges from 0.1 micrometer to 500 micrometers. 
     
     
         20 . The ceramic matrix composite of  claim 18 , wherein an aspect ratio of the inorganic filler particles ranges from 1 to 100.