Ceramic matrix composite and method of fabricating ceramic matrix composite part

Abstract

To provide an improved ceramic matrix composite.SOLUTION: A ceramic matrix composite includes a plurality of ceramic fibers, an interface coating disposed on the plurality of ceramic fibers, and a ceramic matrix surrounding the plurality of ceramic fibers. The ceramic matrix includes a silicon carbide phase and an oxide phase. The oxide phase includes at least two of cordierite, mullite, sapphirine, spinel, alumina, periclase, and forsterite. A method of fabricating a ceramic matrix composite is also disclosed.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to ceramic components. [Background technology]

[0002] A gas turbine engine typically includes a fan section, a compressor section, a combustor section, and a turbine section. Air entering the compressor section is compressed and sent to the combustion section, where it is mixed with fuel and ignited, generating a high-velocity exhaust gas flow. The high-velocity exhaust gas flow expands through the turbine section, powering the compressor and fan sections. The compressor section typically includes low- and high-pressure compressors, and the turbine section includes low- and high-pressure turbines.

[0003] One example of a ceramic material is a ceramic matrix composite ("CMC"), which typically contains a ceramic-based material with a ceramic-based reinforcement (such as fibers). Because of their high heat resistance, CMCs are being considered for use in gas turbine engines, which have areas that operate at very high temperatures. For example, CMCs are being considered for use in the compressor section and compressor / turbine section airfoils and / or blade outer air seals ("BOAS"). Despite their excellent heat resistance, implementing CMC parts in gas turbine engines presents unique challenges. Summary of the Invention [Problem to be solved by the invention]

[0004] The object of the present invention is therefore to improve ceramic matrix composites of the type mentioned at the outset so that the above-mentioned disadvantages are reduced. [Means for solving the problem]

[0005] A ceramic matrix composite according to an exemplary embodiment of the present disclosure includes, among other things, a plurality of ceramic fibers, an interfacial coating disposed on the plurality of ceramic fibers, and a ceramic matrix surrounding the plurality of ceramic fibers. The ceramic matrix includes a silicon carbide phase and an oxide phase. The oxide phase includes at least two of cordierite, mullite, sapphirine, spinel, alumina, periclase, and forsterite.

[0006] In a further example of the foregoing, the oxide phase includes at least one of alumina and mullite.

[0007] In a further example of any of the foregoing, the oxide phase includes at least one of cordierite and sapphirine.

[0008] In a further example of any of the foregoing, the oxide phase includes periclase.

[0009] In a further example of any of the foregoing, the oxide phase includes at least one of spinel and forsterite.

[0010] In a further example of any of the foregoing, the matrix further comprises particulate silicon carbide.

[0011] In a further example of any of the foregoing, the particulate silicon carbide comprises about 10 to about 20 volume percent of the matrix.

[0012] In a further example of any of the foregoing, the plurality of fibers is a woven silicon carbide fabric.

[0013] In a further example of any of the foregoing, the plurality of fibers comprises about 30 to about 50 volume percent of the ceramic matrix composite.

[0014] In a further example of any of the foregoing, the matrix includes about 10 to about 30 volume percent of a silicon carbide phase and about 20 to about 90 volume percent of an oxide phase.

[0015] In a further example of any of the foregoing, at least about 75% by volume of the oxide phases include cordierite, mullite, and sapphirine.

[0016] In a further example of any of the foregoing, at least about 75% by volume of the oxide phases include periclase, spinel, and forsterite.

[0017] A ceramic matrix composite according to an exemplary embodiment of the present disclosure includes, among other things, a plurality of ceramic fibers, an interfacial coating disposed on the plurality of ceramic fibers, and a ceramic matrix surrounding the plurality of ceramic fibers. The ceramic matrix includes a silicon carbide phase and an oxide phase. The oxide phase includes cordierite, mullite, and sapphirine.

[0018] In a further example of the foregoing, the matrix further comprises particulate silicon carbide.

[0019] In a further example of any of the foregoing, the matrix includes about 10 to about 30 volume percent of a silicon carbide phase and about 20 to about 40 volume percent of an oxide phase.

[0020] A ceramic matrix composite according to an exemplary embodiment of the present disclosure includes, among other things, a plurality of ceramic fibers, an interfacial coating disposed on the plurality of ceramic fibers, and a ceramic matrix surrounding the plurality of ceramic fibers. The ceramic matrix includes a silicon carbide phase and an oxide phase. The oxide phase includes spinel, periclase, and at least one of forsterite and enstatite.

[0021] In a further example of the foregoing, the matrix further comprises particulate silicon carbide.

[0022] In a further example of any of the foregoing, the matrix includes about 10 to about 30 volume percent of a silicon carbide phase and about 20 to about 40 volume percent of an oxide phase.

[0023] A method of manufacturing a ceramic matrix composite part according to an exemplary embodiment of the present disclosure includes, among other things, placing a plurality of fibers in a preform, applying an interfacial coating to the plurality of fibers, infiltrating the preform with a silicon carbide matrix phase, infiltrating the preform with precursors of a first component of an oxide phase and a second component of the oxide phase such that the first component and the second component penetrate the porosity of the silicon carbide matrix phase, and heat treating the preform, whereby the precursor is converted to the second component.

[0024] In a further example of the foregoing, the first component is alumina, mullite, spinel, magnesia, or a mixture thereof.

[0025] In a further example of any of the foregoing, the first component is infiltrated into the preform via a slurry.

[0026] In a further example of any of the foregoing, the precursor is infiltrated into the preform in the form of a molten glass.

[0027] In a further example of any of the foregoing, the molten glass includes at least one of magnesium oxide, aluminum oxide, and silicon dioxide.

[0028] In a further example of any of the foregoing, after heat treatment, the oxide phases include at least one of cordierite, sapphirine, spinel, and forsterite.

[0029] A ceramic matrix composite according to an exemplary embodiment of the present disclosure includes, among other things, a plurality of ceramic fibers and a chemical vapor infiltration deposited interfacial coating disposed on the plurality of ceramic fibers. The interfacial coating includes at least one layer of silicon carbide. The ceramic matrix composite also includes a ceramic matrix surrounding the plurality of ceramic fibers. The ceramic matrix includes a silicon carbide phase and an oxide phase. The oxide phase includes at least one of cordierite, mullite, sapphirine, spinel, alumina, periclase, and forsterite.

[0030] In a further example of the foregoing, the oxide phase includes at least one of alumina and mullite.

[0031] In a further example of any of the foregoing, the oxide phase includes periclase.

[0032] In a further example of any of the foregoing, the matrix further comprises particulate silicon carbide.

[0033] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings accompanying the detailed description can be briefly described as follows: [Brief explanation of the drawings]

[0034] [Figure 1] 1 illustrates an example of a gas turbine engine. [Figure 2] 2A-2C illustrate examples of CMC components for the gas turbine engine of FIG. 1. [Figure 3] 3A-3C illustrate pores in the example CMC part of FIG. 2 during manufacture of the CMC part. DETAILED DESCRIPTION OF THE INVENTION

[0035] 1 illustrates a schematic representation of a gas turbine engine 20. The gas turbine engine 20 is generally disclosed herein as a two-spool turbofan incorporating a fan section 22, a compressor section 24, a combustor section 26, and a turbine section 28. The fan section 22 drives air along a bypass flowpath B within a bypass duct defined within the nacelle 15 and along a core flowpath C for compression and communication with the combustor section 26 and subsequent expansion through the turbine section 28. While the disclosed, non-limiting embodiment is shown as a two-spool turbofan gas turbine engine, it should be understood that the concepts described herein are not limited to use with two-spool turbofans, as the present teachings may also be applied to other types of turbine engines, including three-spool configurations.

[0036] The exemplary engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about the engine's central longitudinal axis A relative to an engine static structure 36 via a number of bearing systems 38. It should be understood that different bearing systems 38 may alternatively or additionally be provided in different locations, and the locations of the bearing systems 38 may be varied as appropriate depending on the application.

[0037] The low-speed spool 30 typically includes an inner shaft 40 that interconnects a first (or low-pressure) compressor 44 and a first (or low-pressure) turbine 46. The inner shaft 40 is connected to the fan 42 via a speed-changing mechanism, shown in the exemplary gas turbine engine 20 as a gear structure 48, for driving the fan 42 at a lower speed than the low-speed spool 30. The high-speed spool 32 includes an outer shaft 50 that interconnects a second (or high-pressure) compressor 52 and a second (or high-pressure) turbine 54. A combustor 56 is located in the exemplary gas turbine 20 between the high-pressure compressor 52 and the high-pressure turbine 54. A mid-turbine frame 57 of the engine static structure 36 may typically be located between the high-pressure turbine 54 and the low-pressure turbine 46. The mid-turbine frame 57 further supports a bearing system 38 within the turbine section 28. The inner shaft 40 and the outer shaft 50 are concentric and rotate via the bearing system 38 about a central longitudinal axis A of the engine that is collinear with the longitudinal axis A of the inner shaft 40 and the outer shaft 50.

[0038] The core airflow is compressed by the low-pressure compressor 44 and then the high-pressure compressor 52, mixed with fuel and combusted in the combustor 56, and then expanded through the high-pressure turbine 54 and the low-pressure turbine 46. A mid-turbine frame 57 includes airfoils 59 in the core airflow path C. The low-pressure turbine 46 includes airfoils 60. The turbines 46, 54 rotate the respective low-speed spool 30 and high-speed spool 32 in response to the expansion. It will be appreciated that the locations of the fan section 22, compressor section 24, combustor section 26, turbine section 28, and fan drive gear system 48 may each be varied. For example, the gear system 48 may be located aft of the low-pressure compressor, or aft of the combustor section 26, or even aft of the turbine section 28, and the fan 42 may be located forward or aft of the gear system 48.

[0039] In one example, engine 20 is a high-bypass gear aircraft engine. In a further example, engine 20 has a bypass ratio greater than about 6, and in an exemplary embodiment, greater than about 10, gear structure 48 is an epicyclic gear train, such as a planetary gear system or other gear system, having a gear reduction ratio greater than about 2.3, and low-pressure turbine 46 has a pressure ratio greater than about 5. In one disclosed embodiment, engine 20 has a bypass ratio greater than about 10 (10:1), the fan diameter is significantly larger than the diameter of low-pressure compressor 44, and low-pressure turbine 46 has a pressure ratio greater than about 5:1. The pressure ratio of low-pressure turbine 46 is the pressure measured before the inlet of low-pressure turbine 46 relative to the pressure at the outlet of low-pressure turbine 46 before the exhaust nozzle. Gear structure 48 may also be an epicyclic gear train, such as a planetary gear system or other gear system, having a gear reduction ratio greater than about 2.3:1 and less than about 5:1. However, it should be understood that the above parameters are merely exemplary of one embodiment of a geared engine, and that the present invention is applicable to other gas turbine engines, including direct drive turbofans.

[0040] Due to the high bypass ratio, a significant amount of thrust is provided by the bypass flow B. The fan section 22 of the engine 20 is designed to cruise at specific flight conditions, typically at about Mach 0.8 and about 35,000 feet (10,668 meters). At flight conditions of Mach 0.8 and 35,000 feet (10,668 meters), when the engine is at its highest fuel consumption (also referred to as "bucket cruise thrust specific fuel consumption ('TSFC')"), is an industry standard parameter of lbm of fuel burned divided by the lbf of thrust the engine produces at its minimum point. The "low fan pressure ratio" is the overall pressure ratio of the fan blades alone, without the use of a fan exit guide vane ("FEGV") system. According to one non-limiting embodiment, the low fan pressure ratio disclosed herein is less than about 1.45. "Low corrected fan tip speed" is the actual fan tip speed (ft / sec) divided by the industry standard temperature correction of [(Tram°R) / (518.7°R)] 0.5. According to one non-limiting embodiment, the "low corrected fan tip speed" disclosed herein is less than about 1150 ft / sec (350.5 m / sec).

[0041] Ceramic matrix composites (CMCs) can be used in various regions of the engine described above and shown in Figure 1. For example, CMC components, or components that are at least partially CMC, can be used in the combustor section 26 or the turbine / compressor sections 28 / 24. Figure 2 shows a non-limiting example of a CMC component 100, which is, for example, an airfoil 100 used in the turbine section 28 (see also Figure 1), but in other examples, can be any other component of the engine 20.

[0042] As shown in FIG. 2, which is a cross-sectional view of a CMC component 100, the component 100 generally includes a plurality of ceramic-based fibers 102 disposed within a ceramic-based matrix 104. While the fibers 102 in FIG. 2 are shown arranged in a unidirectional pattern, other patterns are contemplated, including various weave patterns known in the art. In some examples, the fibers 102 are arranged in bundles or bundles. The fibers 102 may be silicon carbide fibers, although other materials known in the art are contemplated. In certain examples, the fibers 102 comprise about 30 to about 50 volume percent of the CMC component 100.

[0043] An interfacial coating 106 is disposed on each of the fibers 102. In one example, the interfacial coating 106 is silicon carbide. In one example, the interfacial coating 106 is boron nitride. The interfacial coating 106 may also include multiple layers of silicon carbide, boron nitride, or both. In one example, the interfacial coating 106 is at least about 0.1 microns thick. In a further example, the interfacial coating 106 is at least about 0.5 microns thick. In yet a further example, the interfacial coating 106 is at least about 2 microns thick. As described further below, the interfacial coating 106 is sufficiently thick to protect the fibers 102 during formation of the CMC component 100. In one example, the interfacial coating 106 is a dual layer, with an inner layer being boron nitride at least 0.1 microns thick and an outer layer being silicon carbide at least 0.1 microns thick. In a particular example, the interfacial coating 106 is a bilayer in which the inner layer is a 200 nm thick layer of boron nitride and the outer layer is a 500 nm thick layer of silicon carbide.

[0044] In a particular example, the interfacial coating 106 is applied by chemical vapor infiltration (CVI), which produces silicon carbide and boron nitride with different microstructures.

[0045] While CMC materials have excellent capabilities for use in the high-temperature environments of gas turbine engines 20, conventional CMC components often include coatings, such as thermal and / or environmental barrier coatings, to improve temperature and environmental resistance. However, applying coatings can alter the dimensions and shape of the CMC component. Furthermore, manufacturing conventional CMC components is often expensive and requires long processing times due to challenges in forming a matrix surrounding the fibers. For example, the matrix may be manufactured using chemical vapor infiltration (CVI), which requires long deposition times, or polymer infiltration and pyrolysis (PIP), which requires many infiltration steps. Both CVI and PIP use expensive precursors with low yields. At least partially processing the matrix through other infiltration techniques, such as those described below, can reduce the manufacturing cost and processing time of CMC components and, in some cases, mitigate the need for additional temperature and / or environmental protection provided by coatings.

[0046] As such, the CMC components 100 described herein have a matrix 104 that has improved heat resistance due to the inclusion of carbide and oxide materials, allowing the coating to be omitted entirely or to be thinner than conventional CMC components 100.

[0047] The matrix 104 includes a silicon carbide phase 104a and an oxide phase 104b. The silicon carbide phase 104a comprises about 10 to about 70 volume percent of the matrix 104. The oxide phase 104b comprises about 20 to about 60 volume percent of the matrix 104. In some examples, the matrix 104 further includes particulate silicon carbide 104c dispersed within the matrix 104. In particular examples, the particulate silicon carbide comprises about 10 to about 20 volume percent of the matrix.

[0048] The oxide phase is cordierite (Mg2Al4Si5O 18 ), mullite (Al6Si2O 13 ), Sapphirine (Mg4Al 10 SiO 23), spinel (MgAlO), alumina (AlO), periclase (MgO), enstatite (MgSiO), and forsterite (MgSiO). In certain examples, oxide phase 104b includes at least one of alumina and mullite, and at least one of cordierite, sapphirine, spinel, and forsterite. In certain examples, at least about 75 volume percent of oxide phase 104b includes cordierite, mullite, and sapphirine. The oxide phase has a good thermal expansion coefficient that matches other aspects of CMC component 100, such as fibers 102 and interface coating 106.

[0049] Matrix 104 has thermal expansion, thermal conductivity, and density properties that are compatible with other aspects of CMC component 100 and selected based on the intended use of CMC component 100. In certain examples, matrix 104 is thermally stable up to temperatures of at least about 2600 degrees F. That is, matrix 104, and more generally CMC component 100, can be exposed to temperatures up to about 2600 degrees F and still be suitable for use.

[0050] In a particular example, the CMC component 100 includes a silicon carbide fiber fabric 102 that comprises about 30 to about 50 volume percent of the CMC component 100. The interfacial coating 106 is silicon carbide. The CMC component 100 also includes a matrix 104 that includes about 10 to about 30 volume percent of a silicon carbide phase 104a, about 20 to about 60 volume percent of an oxide phase 104b, with at least about 75 volume percent of the oxide phase including cordierite, mullite, and sapphirine.

[0051] In a particular example, the CMC component 100 includes a silicon carbide fiber fabric 102 that comprises about 30 to about 50 volume percent of the CMC component 100. The interfacial coating 106 is silicon carbide. The CMC component 100 also includes a matrix 104 that includes about 10 to about 30 volume percent silicon carbide phase 104a, about 20 to about 40 volume percent oxide phase 104b, and about 10 to about 20 volume percent particulate silicon carbide 104c, wherein at least about 75 volume percent of the oxide phase includes cordierite, mullite, and sapphirine.

[0052] The CMC component 100 can be manufactured as follows: The fibers 102 are placed in a preform. The interfacial coating 106 is applied to the fibers 102 by a vapor deposition process. The silicon carbide phase 104a of the matrix 104 is then infiltrated into the preform. If the interfacial coating 106 is also silicon carbide, the interfacial coating 106 and the matrix 104 can be applied / infiltrated to the preform using the same vapor deposition process. In some examples, process parameters can be adjusted so that the interfacial coating 106 is initially denser than the matrix 104, as is known in the art.

[0053] The preform is then infiltrated with a slurry containing at least one component of oxide phase 104b and / or precursor of oxide phase 104b, and optional particulate silicon carbide, in a carrier fluid. The slurry penetrates the pores of the matrix 104 and deposits the component or precursor of oxide phase 104b therein. In a particular example, the oxide phase 104b in the slurry includes at least one of alumina and mullite.

[0054] In some examples, the precursor of the oxide phase 104b component is a glass, such as magnesium oxide, aluminum oxide, and / or silicon dioxide, or a combination thereof. The glass may be applied to the preform in a molten state rather than being introduced to the preform via a slurry, and then poured into a composite by any known method. In a particular example, the molten glass is about 33 mol% MgO, about 19 mol% AlO 1.5 In another particular example, the molten glass contains about 44 mole % of MgO, AlO, and about 44 mole % of SiO. 1.5 The four glass series include a series of molten glasses, each with a different eutectic point, including SiO2, SiO2, and SiO2. The various eutectic points allow for greater flexibility in choosing the phase that results after heat treatment, as discussed below. Table 1 shows examples of four glass series:

[0055] [Table 1]

[0056] After the molten glass is infiltrated into the preform, MgO or AlO 1.5 Glass particles, such as glass particles, remain within the pores of matrix 104. The glass particles, in some examples, may be less than about 100 microns in diameter. In further examples, the glass particles are less than about 25 microns in diameter.

[0057] In a particular example, the slurry includes alumina. For example, the solids content of the slurry can be at least about 70% alumina. In a more specific example, the remainder of the solids content of the slurry is silicon carbide particles. After the slurry is infiltrated into the preform, about 33% (one-third) to about 67% (two-thirds) of the porosity of the matrix 104 is filled with the solid components of the slurry. FIG. 3 shows a preform 200 having pores 202. Solid slurry components 204 are disposed within the pores 202. In a particular example, the slurry deposits alumina within the pores such that about 35% of the porosity of the matrix 104 is filled with alumina. In a further example, if used, about 15% of the porosity of the matrix 104 is filled with silicon carbide particles.

[0058] After infiltration with molten glass, matrix 104 has a ratio of volume of alumina to volume of molten glass in the range of about 1:2 to 2:1. In a particular example, matrix 104 has a ratio of volume of alumina to volume of molten glass in the range of about 1:2 to 1:1. In another example, matrix 104a has a ratio of volume of alumina to volume of molten glass in the range of about 0.51 to about 1.16, which results in the formation of cordierite, sapphirine, and mullite after subsequent heat treatment, as described below.

[0059] In another example, the slurry includes mullite and alumina. For example, the solids content of the slurry can be at least about 50% alumina and at least about 20% mullite. The matrix 104a has a volume ratio of alumina and mullite to the volume of molten glass ranging from about 0.75 to about 1.25, resulting in the presence of at least one of cordierite and sapphirine after subsequent heat treatment, as described below. In a particular example, the heat treatment results in the presence of cordierite, sapphirine, and mullite. In this case, the ratio of alumina and mullite to glass is high, and the resulting matrix 104 contains more mullite and cordierite, resulting in a lower coefficient of thermal expansion of the matrix 104 compared to a matrix without the oxide phase 104b.

[0060] In another example, the slurry includes spinel and alumina. For example, the solids content of the slurry can be at least about 60% alumina and at least about 10% spinel. The matrix 104a has a ratio of the volume of alumina and spinel to the volume of molten glass ranging from about 0.75 to about 1.25, which results in the formation of cordierite, sapphirine, and mullite after subsequent heat treatment, as described below. In this case, the resulting matrix 104 contains more sapphirine, thereby improving the thermal conductivity of the matrix compared to a matrix without the oxide phase 104b.

[0061] In a particular example, the slurry includes MgO (magnesia). For example, the solid content of the slurry can be at least about 70% MgO. In a more specific example, the remainder of the solid content of the slurry is silicon carbide particles. After the slurry is infiltrated into the preform, about 33% (one-third) to about 67% (two-thirds) of the porosity of the matrix 104 is filled with the solid components of the slurry. FIG. 3 shows a preform 200 having pores 202. Solid slurry components 204 are disposed within the pores 202. In a particular example, the slurry deposits MgO within the pores such that about 35% of the porosity of the matrix 104 is filled with MgO. In a further example, if used, about 15% of the porosity of the matrix 104 is filled with silicon carbide particles.

[0062] After infiltration with molten glass, matrix 104 has a ratio of MgO volume to molten glass volume ranging from about 1:2.5 to 2:1. In a particular example, matrix 104 has a ratio of MgO volume to molten glass volume ranging from about 1:2.5 to 1:1. In another example, matrix 104a has a ratio of magnesia volume to molten glass volume ranging from about 0.4 to about 1.0, resulting in the presence of at least one of spinel (MgAlO) and forsterite (MgSiO). In a further example, heat treatment results in the presence of spinel (MgAlO), forsterite (MgSiO), and periclase (magnesia, a crystalline form of MgO).

[0063] A matrix 104 containing periclase, spinel, and forsterite can be stable at temperatures above 1600° C. The thermal expansion coefficients of the periclase, spinel, and forsterite phases are each 25% greater than that of SiC.

[0064] The preform is then heat-treated to convert the precursor to the desired oxide phase 104b. During the heat treatment, crystals of various phases grow from the glass particles. The heat treatment temperature is selected to form the desired oxide phase 104b according to the known properties of the phase. The heat treatment can include multiple steps performed at different temperatures, as known in the art. In a specific example, the heat treatment is performed at a temperature up to about 1450°C, which promotes the formation of sapphirine, limits the formation of spinel, and allows equilibrium to be reached between the phases present. In another specific example, the heat treatment is performed above about 1350°C. In another specific example, the 1450°C heat treatment is followed by a heat treatment above 1100°C.

[0065] During application of the slurry and / or molten glass and subsequent heat treatment, the interfacial coating 106 protects the fibers 102 from interaction with the slurry and / or molten glass components, which may be particularly reactive with silicon carbide, i.e., the fibers 102 remain substantially intact from the preform to the CMC component 100.

[0066] In one particular example, the CMC component 100 is fabricated as follows: A silicon carbide fiber fabric 102 is placed in a preform. A silicon carbide interface coating 106 and matrix 104 are deposited on the fibers 102 by a vapor deposition process. A slurry containing alumina, mullite, and / or silicon carbide fibers is infiltrated into the matrix 104. The matrix 104 is then coated with a mixture of 33 mol % MgO, approximately 19 mol % AlO, and a silicon carbide interfacial coating 106. 1.5A glass containing about 44 mol % SiO2 is melted into a matrix 104 at a temperature of about 1350 to about 1500°C. After infiltration of the slurry and molten glass, the porosity of the matrix 104 contains about 25 to about 75 volume % alumina, about 35 to about 80 volume % mullite, and about 1 to about 50 volume % silicon carbide particles. The CMC component 100 is heat treated at about 1100 to 1400°C. The resulting CMC component 104 comprises about 30 to about 50 volume % fibers 102 and a matrix 104 containing about 10 to about 30 volume % silicon carbide phase 104a and about 20 to about 60 volume % oxide phase 104b, with at least about 75 volume % of the oxide phase 104b comprising cordierite, mullite, and sapphirine.

[0067] Although combinations of features are shown in the illustrated examples, not all features need to be combined to realize the benefits of various embodiments of the present disclosure. In other words, a system designed in accordance with an embodiment of the present disclosure will not necessarily include all of the features shown in any of the figures or all of the portions schematically shown in the figures. Furthermore, selected features of one exemplary embodiment may be combined with selected features of other exemplary embodiments.

[0068] The foregoing description is exemplary in nature, rather than limiting. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.

Claims

1. 1. A ceramic matrix composite comprising: A plurality of ceramic fibers; an interfacial coating disposed on the plurality of ceramic fibers; a ceramic matrix surrounding the plurality of ceramic fibers, the ceramic matrix including a silicon carbide phase and an oxide phase; wherein the oxide phase comprises at least two of cordierite, mullite, sapphirine, spinel, alumina, periclase, and forsterite.

2. The ceramic matrix composite of claim 1 , wherein the oxide phase comprises at least one of alumina and mullite.

3. The ceramic matrix composite of claim 2 , wherein the oxide phase comprises at least one of cordierite and sapphirine.

4. The ceramic matrix composite of claim 1 , wherein the oxide phase comprises periclase.

5. The ceramic matrix composite of claim 4 , wherein the oxide phase comprises at least one of spinel and forsterite.

6. The ceramic matrix composite of claim 1 , wherein the matrix further comprises particulate silicon carbide.

7. The ceramic matrix composite of claim 6, wherein the particulate silicon carbide comprises about 10 to about 20 volume percent of the matrix.

8. The ceramic matrix composite of claim 1 , wherein the plurality of fibers is a woven silicon carbide fabric.

9. The ceramic matrix composite of claim 8, wherein the plurality of fibers comprises about 30 to about 50 volume percent of the ceramic matrix composite.

10. The ceramic matrix composite of claim 1, wherein the matrix comprises about 10 to about 30 volume percent of the silicon carbide phase and about 20 to about 90 volume percent of the oxide phase.

11. 11. The ceramic matrix composite of claim 10, wherein at least about 75 volume percent of the oxide phases comprises cordierite, mullite, and sapphirine.

12. 11. The ceramic matrix composite of claim 10, wherein at least about 75 volume percent of the oxide phases comprises periclase, spinel, and forsterite.

13. 1. A ceramic matrix composite comprising: A plurality of ceramic fibers; an interfacial coating disposed on the plurality of ceramic fibers; a ceramic matrix surrounding the plurality of ceramic fibers, the ceramic matrix including a silicon carbide phase and an oxide phase; wherein the oxide phases include cordierite, mullite, and sapphirine.

14. The ceramic matrix composite of claim 13 , wherein the matrix further comprises particulate silicon carbide.

15. 14. The ceramic matrix composite of claim 13, wherein the matrix comprises about 10 to about 30 volume percent of the silicon carbide phase and about 20 to about 40 volume percent of the oxide phase.

16. 1. A ceramic matrix composite comprising: A plurality of ceramic fibers; an interfacial coating disposed on the plurality of ceramic fibers; a ceramic matrix surrounding the plurality of ceramic fibers, the ceramic matrix including a silicon carbide phase and an oxide phase; wherein the oxide phase comprises spinel, periclase, and at least one of forsterite and enstatite.

17. 17. The ceramic matrix composite of claim 16, wherein the matrix further comprises particulate silicon carbide.

18. 17. The ceramic matrix composite of claim 16, wherein the matrix comprises about 10 to about 30 volume percent of the silicon carbide phase and about 20 to about 40 volume percent of the oxide phase.

19. 1. A method for manufacturing a ceramic matrix composite component, comprising: disposing a plurality of fibers in a preform; applying an interfacial coating to the plurality of fibers; infiltrating the preform with a silicon carbide matrix phase; infiltrating the preform with precursors of a first component of an oxide phase and a second component of the oxide phase such that the first component and second component penetrate the porosity of the silicon carbide matrix phase; and heat treating the preform, wherein the heat treatment converts the precursor to the second component.

20. 20. The method of claim 19, wherein the first component is alumina, mullite, spinel, magnesia, or a mixture thereof.

21. 20. The method of claim 19, wherein the first component is infiltrated into the preform via a slurry.

22. 20. The method of claim 19, wherein the precursor is infiltrated into the preform in the form of a molten glass.

23. 20. The method of claim 19, wherein the molten glass comprises at least one of magnesium oxide, aluminum oxide, and silicon dioxide.

24. 20. The method of claim 19, wherein after the heat treatment, the oxide phases comprise at least one of cordierite, sapphirine, spinel, and forsterite.

25. 1. A ceramic matrix composite comprising: A plurality of ceramic fibers; a chemical vapor infiltration deposition interfacial coating disposed on the plurality of ceramic fibers, the interfacial coating comprising at least one layer of silicon carbide; a ceramic matrix surrounding the plurality of ceramic fibers, the ceramic matrix including a silicon carbide phase and an oxide phase; Equipped with The ceramic matrix composite, wherein the oxide phase comprises at least one of cordierite, mullite, sapphirine, spinel, alumina, periclase, and forsterite.

26. 26. The ceramic matrix composite of claim 25, wherein the oxide phase comprises at least one of alumina and mullite.

27. 26. The ceramic matrix composite of claim 25, wherein the oxide phase comprises periclase.

28. 26. The ceramic matrix composite of claim 25, wherein the matrix further comprises particulate silicon carbide.

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