Development and Characterization of Continuous SiC Fiber‐Reinforced HfB2‐Based UHTC Matrix Composites Using Polymer Impregnation and Slurry Infiltration Techniques

Abstract

This paper discusses the development of continuous SiC fiber‐reinforced HfB2‐SiC composite laminates. A range of techniques, based on resin‐based precursors and slurries, for infiltrating porous SiC preforms with HfB2 powder were developed. While resin‐based precursors proved to be ineffective due to low HfB2 yield and poor adhesion, the slurry infiltration techniques were effective to varying degrees. The greatest pore filling and composite densities were achieved using pressure and vibration‐assisted pressure infiltration techniques. SiCf/HfB2‐SiC laminates were subsequently developed via lamination, cure and pyrolysis of fabrics using a HfB2‐loaded polymeric SiC precursor, followed by HfB2 slurry infiltration and preceramic polymer infiltration and pyrolysis (PIP). Repeated PIP processing, for 6–10 cycles, resulted in density increases, from the 3.03–3.22 g/cm3 range after HfB2 slurry infiltration, to 3.97–4.03 g/cm3 after PIP processing. Correspondingly, there was a decrease in open porosity from approximately 52% to less than 11%. The matrix consisted of discreet, lightly sintered HfB2 particles dispersed in SiC. The PIP SiC matrix was primarily nanocrystalline after 1300°C pyrolysis, but experienced grain growth with further heat treatment at 1600°C.