Densification of Ceramic Matrix Composite Preforms by Si2N2O Formed by Reaction of Si with SiO2 under High Nitrogen Pressure. Part 1: Materials Synthesis

Abstract

Ceramic matrix composites (CMCs) have been designed and developed for extreme operating environments. The aim of the present study is to look for a rapid densification process providing a high level of material performance. The fibrous preform was made of Hi-Nicalon S fibers woven in a 3D interlock weave. The matrix was composed of Si2N2O prepared inside the CMCs by reacting a mixture of Si and SiO2 under high nitrogen pressure (1 to 3 MPa). Silica was either impregnated by slurry or obtained by oxidation of silicon grains inside the preform. The synthesis reaction was initiated by heating the impregnated preform by means of a carbon resistor submitted to Joule effect. Composition, homogeneity and porosity of the formed matrix were studied and interpreted as a function of the experimental parameters (nitrogen pressure, heating rate of the preform) as well as the recorded thermal history of the process. The present results show that the matrix formation is almost completed in less than one minute. Melting of silicon has a major influence on the process. Competition was observed between the formation of Si3N4 and Si2N2O, which could be mainly controlled by the heating rate of the preform and the nitrogen partial pressure.