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| The present invention relates to a process for producing fiber-reinforced silicon carbide composites, which are suitable for a variety of applications requiring improved toughness, such as aerospace high-temperature structural members, gas turbine members, fusion reactor materials, furnace members, heater materials, and artificial bones. According to the invented process, dense fiber-reinforced silicon carbide composites can easily be produced as follows; 1) Cover a fiber bundle region of a two-dimensional fiber reinforced silicon carbide composite with amorphous carbon derived from an impregnated resin to densify the region. 2) Form open pores in spaces between the fibers or between the fibrous woven fabrics with the use of reaction sintering of a phenol resin, for example with silicon powder. 3) Infiltrate molten silicon into the open pores. In addition, it is advantageous that the invented process can easily yield green bodies (molded parts) having complicated shapes because hot pressing or other techniques are not required. Furthermore, the process can yield dense composites without deteriorating the fiber, as molten silicon is infiltrated in the last step.first embodiment invented namely continuous woven fabric fibrous reinforcement impregnated dissolved resin dried further slurry mixture silicon powder prepreg molded shape molding carried dissolving solvent impregnating fiber solution removing drying separately composed product appropriate die temperature generally 100degree 250degree procedure liquid spaces bundles powdered relatively large particle mum unevenly distributed present advantageously following second effective prepregs mixing nonwoven matrix laminated alternate order layer consisiting various individual performed laminating adequate number preferably fine mean exceeding 20 Silicon powders diameter pulverized ball mill green body (molded body) carbonized 900degree 1350degree argon inert atmosphere avoid reaction derived composite regions alone porosity pyrolyzed fired vacuo pressure combination impregnation carbonization repeated predetermined times five 1300degree higher resins porous carbide coated dense molten layers heated 1800degree infiltrate open pores (fired reinforced sintering infiltration treatment proportion inventive range atomic Si/C ranges 01 bycoating phenol words fiber-reinforced freely application occupies 15% 65% volume reinforcing techniques (i) beginning yield (ii) container aggregate preform (iii) |
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