Method of obtaining a fiber-containing composite

Claim 2

A process for producing a composite with a porosity of less than about 20% by volume comprised of boron nitride-coated fibrous material and a matrix phase, said fibrous material component of said coated fibrous material comprising at least about 5% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) depositing boron nitride on a carbon-containing fibrous material producing a coating thereon which leaves no significant portion of said fibrous material exposed; (b) depositing a silicon-wettable material on said boron nitride-coated fibrous material producing a coating thereon which leaves no significant portion of said boron nitride exposed; (c) admixing an infiltration-promoting material containing elemental carbon with the resulting coated fibrous material producing a mixture wherein the fibrous material component of said coated fibrous material comprises at least about 5% by volume of said mixture; (d) forming said mixture into a preform having an open porosity ranging from about 25% by volume to about 90% by volume of the preform; (e) providing an infiltrant comprised of boron and silicon containing elemental boron in solution in silicon in an amount of at least about 0.1% by weight of elemental silicon; (f) contacting said preform with infiltrant-associated infiltrating means whereby said infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant is molten and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite.

Claim 3

The process according to claim 1 wherein said silicon-wettable material is selected from the group consisting of elemental carbon, metal carbide, a metal which reacts with silicon to form a silicide thereof, a metal nitride and a metal silicide.

Claim 4

The process according to claim 1 wherein said preform has an open porosity ranging from about 35% by volume to about 80% by volume.

Claim 5

The process according to claim 1 wherein said infiltration-promoting material is comprised of elemental carbon.

Claim 6

The process according to claim 1 wherein said fibrous material component is elemental carbon.

Claim 7

The process according to claim 1 wherein said fibrous material component is silicon carbide.

Claim 8

The process according to claim 1 wherein said matrix phase is comprised of said silicon carbide and/or boron-containing silicon carbide formed in situ and said infiltrant phase.

Claim 9

The process according to claim 1 wherein said fibrous component of said coated fibrous material comprises from about 10% by volume to about 70% by volume of said composite.

Claim 10

The process according to claim 1, wherein in step (e) said infiltrant is comprised of boron and silicon wherein boron ranges from about 1% by weight to about 3% by weight of silicon containing boron in solution in said silicon ranging from about 1% by weight of silicon to an amount which forms a saturated solution with silicon.

Claim 11

A process for producing a composite with a porosity of less than about 20% by volume comprised of boron nitride-coated fibrous material and a matrix phase, said fibrous material component of said coated fibrous material comprising at least about 5% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) depositing boron nitride on a carboncontaining fibrous material producing a coating thereon which leaves no significant portion of said fibrous material exposed; (b) depositing a silicon-wettable material on said boron nitride-coated fibrous material producing a coating thereon which leaves no significant portion of said boron nitride exposed; (c) admixing an infiltration-promoting material containing elemental carbon with the resulting coated fibrous material producing a mixture wherein the fibrous material component of said coated fibrous material comprises at least about 5% by volume of said mixture; (d) forming said mixture into a preform having an open porosity ranging from about 25% by volume to about 90% by volume of the preform; (e) providing an infiltrant composition comprised of boron and silicon wherein boron ranges from about 0.1% by weight to about 10% by weight of elemental silicon; (f) contacting said preform and said infiltrant composition with infiltrating means whereby molten infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant composition is molten resulting in a molten infiltrant containing elemental boron in solution in an amount ranging from about 0.1% by weight of silicon to an amount which forms a saturated solution with silicon and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite.

Claim 12

A process for producing a composite with a porosity of less than about 20% by volume comprised of boron nitride-coated fibrous material and a matrix phase, said fibrous material component of said coated fibrous material comprising at least about 5% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) depositing boron nitride on a carboncontaining fibrous material producing a coating thereon which leaves no significant portion of said fibrous material exposed; (b) depositing a silicon-wettable material on said boron nitride-coated fibrous material producing a coating thereon which leaves no significant portion of said boron nitride exposed; (c) admixing an infiltration-promoting material containing elemental carbon with the resulting coated fibrous material producing a mixture wherein the fibrous material component of said coated fibrous material comprises at least about 5% by volume of said mixture; (d) forming said mixture into a preform having an open porosity ranging from about 25% by volume to about 90% by volume of the preform; (e) providing an infiltrant composition comprised of boron and silicon wherein boron ranges from about 0.1% by weight to about 10% by weight of elemental silicon; (f) contacting said preform and said infiltrant composition with infiltrating means whereby molten infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant composition is molten resulting in a molten infiltrant containing elemental boron in solution in an amount ranging from about 0.1% by weight of silicon to an amount which forms a saturated solution with silicon and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite.

Claim 13

The process according to claim 10, wherein in step (e) said infiltrant composition is comprised of boron and silicon wherein boron ranges from about 1% by weight to about 3% by weight of silicon and wherein in step (g) said molten infiltrant contains elemental boron in solution in an amount ranging from about 1% by weight of silicon to an amount which forms a saturated solution with silicon.

Claim 14

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated fibrous material and a matrix phase, said fibrous material component of said coated fibrous material comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boroncontaining silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) depositing boron nitride on a carbon-containing fibrous material producing a coating thereon which leaves no significant portion of said fibrous material exposed; (b) depositing a silicon-wettable material on said boron nitride-coated fibrous material producing a coating thereon which leaves no significant portion of said boron nitride exposed; (c) admixing an infiltration-promoting material containing elemental carbon with the resulting coated fibrous material producing a mixture wherein the fibrous material component of said coated fibrous material comprises at least about 5% by volume of said mixture and is sufficient to produce said composite; (d) forming said mixture into a preform having an open porosity ranging from about 35% by volume to about 80% by volume of the preform; (e) providing an infiltrant comprises of boron and silicon wherein boron ranges from about 1% by weight to about 3% by weight of elemental silicon and contains boron in solution in an amount ranging from about 1% by weight of silicon to an amount which forms a saturated solution with silicon; (f) contacting said preform with infiltrant-associated infiltrating means whereby said infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant is molten and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite.

Claim 15

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated fibrous material and a matrix phase, said fibrous material component of said coated fibrous material comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boroncontaining silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) depositing boron nitride on a carbon-containing fibrous material producing a coating thereon which leaves no significant portion of said fibrous material exposed; (b) depositing a silicon-wettable material on said boron nitride-coated fibrous material producing a coating thereon which leaves no significant portion of said boron nitride exposed; (c) admixing an infiltration-promoting material containing elemental carbon with the resulting coated fibrous material producing a mixture wherein the fibrous material component of said coated fibrous material comprises at least about 5% by volume of said mixture and is sufficient to produce said composite; (d) forming said mixture into a preform having an open porosity ranging from about 35% by volume to about 80% by volume of the preform; (e) providing an infiltrant comprises of boron and silicon wherein boron ranges from about 1% by weight to about 3% by weight of elemental silicon and contains boron in solution in an amount ranging from about 1% by weight of silicon to an amount which forms a saturated solution with silicon; (f) contacting said preform with infiltrant-associated infiltrating means whereby said infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant is molten and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite.

Claim 16

The process according to claim 12, wherein said fibrous material component is elemental carbon.

Claim 17

The process according to claim 12, wherein said fibrous material component is a SiC-containing fibrous material.

Claim 18

The process according to claim 12, wherein said infiltration-promoting material is selected from the group consisting of a powder, a fibrous material and combinations thereof.