US 12,304,869 B2
Composites and methods of forming composites having an increased volume of oxidation resistant ceramic particles
Christopher T. Kirkpatrick, Pueblo West, CO (US)
Assigned to GOODRICH CORPORATION, Charlotte, NC (US)
Filed by GOODRICH CORPORATION, Charlotte, NC (US)
Filed on May 25, 2022, as Appl. No. 17/824,817.
Prior Publication US 2023/0382810 A1, Nov. 30, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. C04B 35/80 (2006.01); C04B 35/626 (2006.01); C04B 35/628 (2006.01); C04B 35/634 (2006.01); C04B 35/657 (2006.01)
CPC C04B 35/80 (2013.01) [C04B 35/6269 (2013.01); C04B 35/62863 (2013.01); C04B 35/62871 (2013.01); C04B 35/62873 (2013.01); C04B 35/62878 (2013.01); C04B 35/62892 (2013.01); C04B 35/63476 (2013.01); C04B 35/657 (2013.01); C04B 2235/3813 (2013.01); C04B 2235/3826 (2013.01); C04B 2235/3873 (2013.01); C04B 2235/5248 (2013.01); C04B 2235/5256 (2013.01); C04B 2235/604 (2013.01); C04B 2235/616 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A method of fabricating a composite component, comprising:
forming a fibrous preform by:
forming a first ceramic particle layer over a first textile layer by depositing a mixture of silicon carbide powder and phenolic resin powder over the first textile layer;
disposing a second textile layer over the first ceramic particle layer;
forming a second ceramic particle layer over the second textile layer; and
disposing a third textile layer over the second ceramic particle layer;
performing a densification process on the fibrous preform, the densification process including coating a plurality of fibers of the fibrous preform with a carbon matrix material; and
performing a silicon melt infiltration process after the densification process, the silicon melt infiltration process including:
infiltrating a plurality of pores defined by the carbon matrix material with a silicon material, and
heating the fibrous preform to a melt temperature until at least 50% of the carbon matrix material and at least a portion of the silicon material are converted into silicon carbide.