Rapid, Cost-Effective, Melt Infiltration Processing of Ultrahigh Temperature Ceramic and Metal Matrix Composites

Aerospace demands for ideal performance and efficiency combined with cost-effectiveness lead to a continuing need for improvements in materials and processes. Ultrahigh temperature capability materials such as ceramic and metal matrix composites can meet operating environment requirements but have historically been slow and costly to produce in geometries required for turbine and airframe structural components. Via a unique combination of processes developed in-house, including fiber interface coating application and melt infiltration of the matrix, Ultramet can rapidly and cost-effectively fabricate a family of ceramic and metal matrix composites suited to ultrahigh temperature applications. Among the materials of interest for aerospace propulsion are carbon fiber-reinforced structural ceramic matrix composites, including refractory carbide matrix composites such as carbon fiber-reinforced zirconium carbide and hafnium carbide, and refractory metal matrix composites. These composites have also been combined with conventional carbon/carbon or lightweight, ultrahigh temperature, insulating foams to produce multilayered structures for an array of aerospace applications. The processing of such composites and recent test results will be presented and discussed.