Fabrication of SiCf/SiC composites through hybrid processing via chemical vapor infiltration, electrophoretic deposition, and liquid silicon infiltration

The present work demonstrates the effectiveness of a novel hybrid process comprising chemical vapor infiltration (CVI), electrophoretic deposition (EPD), and liquid silicon infiltration (LSI) techniques for the successful fabrication of low-porosity SiCf/SiC composites. For this purpose, fiber/matrix interphase dual coating layers of BN and SiC were coated onto SiC fabrics using CVI. A ceramic matrix consisting of SiC and carbon black nanoparticles was then infiltrated into the fine voids of the fabrics using EPD. Finally, LSI was performed to obtain dense microstructures with low porosities by filling the remaining small gaps and reacting Si with C to form SiC. Microstructural results observed by scanning electron microscopy revealed a dense structure with no damage to the fibers. The experimental density was found to be 2.62 g/cc, with an open porosity of 0.55. The room-temperature flexural strength was evaluated to be 111 MPa, and the composites displayed little fiber pull-out.