Fabrication and characterization of carbon fiber reinforced SiC ceramic matrix composites based on 3D printing technology

A novel method has been developed to fabricate carbon fiber reinforced SiC (C-f/SiC) composites by combining 3D printing and liquid silicon infiltration process. Green parts are firstly fabricated through 3D printing from a starting phenolic resin coated carbon fiber composite powder; then the green parts are subjected to vacuum resin infiltration and pyrolysis successively to generate carbon fiber/carbon (C-f/C) preforms; finally, the C-f/C preforms are infiltrated with liquid silicon to obtain C-f/SiC composites. The 3D printing processing parameters show significant effects on the physical properties of the green parts and also the resultant C-f/C preforms, consequently greatly affecting the microstructures and mechanical performances of the final C-f/SiC composites. The overall linear shrinkage of the C-f/SiC composites is less than 3%, and the maximum density, flexural strength and fracture toughness are 2.83 +/- 0.03 g/cm(3), 249 +/- 17.0 MPa and 3.48 +/- 0.24 MPa m(1/2), respectively. It demonstrates the capability of making near net-shape C-f/SiC composite parts with complex structures.