Multi-physics modeling and simulations of reactive melt infiltration process used in fabrication of ceramic-matrix composites (CMCs)

Abstract

Purpose – A multi-physics process model is developed to analyze reactive melt infiltration (RMI) fabrication of ceramic-matrix composite (CMC) materials and components. The paper aims to discuss this issue. Design/methodology/approach – Within this model, the following key physical phenomena governing this process are accounted for: capillary and gravity-driven unsaturated flow of the molten silicon into the SiC/SiC CMC preform; chemical reactions between the silicon melt and carbon (either the one produced by the polymer-binder pyrolysis or the one residing within the dried matrix slurry); thermal-energy transfer and source/sink phenomena accompanying reactive-flow infiltration; volumetric changes accompanying chemical reactions of the molten silicon with the SiC preform and cooling of the as-fabricated CMC component to room temperature; development of residual stresses within, and thermal distortions of, the as-fabricated CMC component; and grain-microstructure development within the SiC matrix during RMI. Findings – The model is validated, at the material level, by comparing its predictions with the experimental and modeling results available in the open literature. The model is subsequently applied to simulate RMI fabrication of a prototypical gas-turbine engine hot-section component, i.e. a shroud. The latter portion of the work revealed the utility of the present computational approach to model fabrication of complex-geometry CMC components via the RMI process. Originality/value – To the authors’ knowledge, the present work constitutes the first reported attempt to apply a multi-physics RMI process model to a gas-turbine CMC component.