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Processing routes for CMCs involve high temperatures can only be employed
with high temperature reinforcements.
The high temperature properties of the reinforcement are also important during
service.
Difference in the coefficients of thermal expansion between the matrix and the
reinforcement lead to thermal stresses after cooling from the processing
temperatures.
(2)
Slurry Infiltration/Impregnation
(3)
(4)
(5)
(6)
Directed Oxidation
Powder Processing
This technique is generally used to fabricate discontinuously reinforced ceramic matrix
composites. The process is only efficient for very small reinforcement such as whiskers and
particulates. Processing of long discontinuous fibers is troublesome as it breaks into short fibers
during mixing and consolidation phase. The basic processing steps involved in powder
processing are mixing (short fibers/ whiskers with slurry of ceramic powder), drying and hot
pressing. Typical fabrication sequence for powder processing is shown in Figure 1.
Binder burn-out
Inspection
Figure 1 Fabrication steps in powder processing
The common challenge in processing of composite materials is voids content in the final product
that can be minimized through uniform dispersion of the reinforcement and matrix powder.
Another way to improve consolidation and diminish porosity is to use super fine ceramic
particles and hot pressing or hot isostatic pressing (HIP). Hot pressing is typically used to
produce various cutting tools that can be used to machine hard-to-machine materials. Optimum
packing can be achieved when the particle size distribution contains about 30% by volume of
small particles and 70% by volume of large particles. Addition of whiskers to slurry can result in
undesirable increase in viscosity. Furthermore, whiskers with a large aspect ratio, greater than
50, tend to tangle and form bundles or loose clumps.
Near net shape can be typically produced by introducing binder to the reinforcement and matrix
through cold forming processes such as uniaxial pressing, cold isostatic pressing, tape casting,
extrusion and injection molding. Secondary operations can be performed on green body without
facilitating any damage after cold pressing. Binders should be burnt out during the consolidation
process.