Processing and Testing of Ultrahigh Temperature Fiber-reinforced Ceramic and Metal Matrix Composites

Ultramet has developed innovative processing for ultrahigh temperature fiber-reinforced ceramic and metal matrix composites. Using a rapid melt infiltration process, Ultramet fabricates high strength fiber-reinforced composite structures that can operate in various hot-gas environments at temperatures in excess of 2800°C. A low temperature process has also been developed to apply fiber interface coatings to protect the fibers during processing and to maximize composite mechanical properties during use. The processing is applicable to ceramic matrices with extremely high melting points including zirconium carbide, hafnium carbide, tantalum carbide, and ceramic alloys, as well as refractory metal matrices. Hot-gas testing of melt infiltrated composite structures in oxidizing environments has been performed at various facilities, and the components survived with low or no erosion. 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. Processing and testing of fiber-reinforced composite materials will be discussed.