JPH0365570A - Fiber-reinforced, ceramic matrix composite member and its manufacture - Google Patents

Abstract

PURPOSE: To obtain a fiber reinforced ceramic composite member having stability to the environment and high strength by changing ceramic particles from a specific slurry into ceramic phase combined in ceramic matrix around the fibers.

CONSTITUTION: A ceramic precursor changed into the ceramic phase by heating, liquid having compatibility with this precusor and a discontinuous material composed of the ceramic particles, are mixed to make matrix mixed material slurry uniformly distributing the ceramic particles and the precursor. Successively, this slurry is spread around plural reinforcing fibers stabilized to oxidation to make a preprag preform. This preform is heated to working temp. necessary to change into the ceramic phase but at the lower than the temp. causing the deterioration of the ceramic phase in the preform in the oxidizing atmosphere. By this heating, the above precursor is changed, and the ceramic particles from the slurry are changed into the ceramic phase combined in the matrix around the fibers and the projective composite member is obtd.

COPYRIGHT: (C)1991,JPO

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a ceramic tiered member and a JFR method of making the same, and more particularly, in one aspect, to a ceramic matrix composite member reinforced with ceramic fibers.

Foreground of the Invention Ceramics are manufactured in the form before high-temperature operation, such as automobile engines, gas turbines, etc., as well as parts for power generation devices, such as fIJ, /-'. The use of certain ceramics is interesting because of their light resistance, b, and high temperature strength. An example of a typical component is a gas turbine engine strut, which is a monotonous ceramic structure that is brittle. Such members cannot be added or mixed in without the assistance of reinforcing structures.
” cannot meet the reliability requirements required in severe applications such as those described above.

In an effort to overcome such drawbacks, several ceramic matrix composites that are resistant to fracture have been reported. They contain fibers of varying size and toughness, such as long fibers or filaments, short fibers or small fiber whiskers. In order to simplify the discussion, in this specification, 1 to 4",
All fibers such as ``fibers'' are simply referred to as ``fibers''. Some fibers may be coated with some substance at i:a6 which avoids violent reactions between the reinforcement and the matrix. Among such coatings are f) carbon or other materials that oxidize when exposed to air at a given high operating temperature. The purpose of including fibers such as No. 72 in the ceramic matrix was to counter brittle fracture behavior.

The problem with 0 when using oxidizing fibers such as carbon (4 and τ) is that the system is unstable (there is a possibility of becoming In other words, the presence of cracks in the ceramic matrix, even minute cracks, can cause oxidizing fibers to come into contact with atmospheric oxygen at high operating temperatures found in the high-temperature parts of power-generating engines. Such oxidation of reinforcing fibers weakens or destroys the fiber structure or its function, rendering the transverse member unacceptably weak.

Another problem is related to the fact that the high temperatures involved in sintering the reinforcing fiber-open ceramic particles limit the types of fibers that can be used. For example, polyolefin fibers degrade above approximately 1000°C, which is much lower than the temperature required for sintering ceramic particles.

Summary of the Invention In one aspect, the present invention includes:
An environment-stable fiber-reinforced ceramic grain I-Rix composite structure consisting of oxidation-stable reinforcing tJtlt (for example, ceramic fibers) and 7 trics dispersed around the fibers. provide. When we use the expression "stable to oxidation" in this specification with respect to fibers, it refers to the temperature and atmosphere (such as air).
shall mean a fiber that is subject to virtually no substantial oxidative and/or environmental degradation under the intended operating conditions of the matrix. .

In this embodiment of the method, the present invention provides a method for dispersing an approximately The ceramic matrix IY1 precursor mixed in a uniform distribution is folded. This slurry is spread 41 as a matrix mixture around oxidatively stable fibers to form a prepreg preform. The preform is heated to processing temperature in an oxidizing atmosphere such as air.

The temperature is at least above the temperature required for the precursor to transform into the ceramic phase and below the temperature that would cause degradation of the ceramic in the preform. According to the invention, such temperature is about 600-10
It can be in the range of 00°C. During such heating, the ceramic precursor changes, for example by decomposition, into a ceramic phase, for example in amorphous or crystalline form.

This ceramic phase binds the ceramic particles from the slurry into the ceramic matrix around the fibers. This reinforced ceramic matrix composite component, preferably almost entirely ceramic oxides bonded together, is stabilized in an oxidizing atmosphere, so it is environmentally stable, has high strength, Moreover, it is highly resistant to destruction.

DESCRIPTION OF THE PREFERRED EMBODIMENT Thanks to the fracture-resistant fiber-reinforced ceramic matrix composite, engineers designing high-temperature components of power-generating engines, such as components of automobile engines, turbine engines, etc., can specify strong and lightweight components. can do.

However, some of such known composites are environmentally unstable when cracking occurs which exposes the oxidizable portion to air. Additionally, some of the known processing processes may leave an undesirable degree of porosity in the product. Additionally, the types of fibers that can be included in sintered ceramic reinforced composites are limited due to the fairly high sintering temperatures required and fiber degradation temperatures below this required sintering temperature. .

The present invention avoids the known problems as described above, and
An improved method for making reinforced ceramic matrix composite parts that are environmentally stable with high strength and high fracture resistance at lower processing temperatures is provided. An important basis of the invention is the use of components that can be stabilized at lower temperatures, so that after heating for stabilization, one product preferably has almost all the ceramic oxides intertwined with each other. It is a connected member. The use of such components eliminates the possibility of oxidative deterioration during use of the component.

Typical examples of ceramic particles used as ceramic materials are Al5St, Cas Hf, B, and Ti.

oxides of elements such as Y and Zr, and mixtures and combinations thereof. Commercially available materials such as A1゜03, SiO2, CaO1Z r
OHf 02 , B N 1T iO2, 2' 3 A l O conflict 2 S i O2, Y203 C
aO.3 A1°03 and various clay and glass fibers. During evaluation of the present invention, ceramic particle sizes ranging from about 75 microns to 0.2 microns in diameter were tested as matrix components. One aspect of the invention relates to the fact that each such ceramic shrinks when fired to high consolidation temperatures when used as a structure.

For example, one form of alumina exhibits linear shrinkage in the range of about 3-4% at 1400°C.

In connection with the present invention, various ceramic precursors that can be used as matrix precursors and infiltrants have been evaluated, as described below. When such precursors are used in combination with ceramic particles as binders, it is possible to produce stable composites at significantly lower processing temperatures. Such precursors, which transform into a ceramic phase by decomposition upon heating, for example, can be in the form of solids or liquids or mixtures thereof for carrying out parts of the invention. Usually these are classified as organometallic compounds, sol-gels or metal salts. The materials used in this evaluation included polycarbosilane, silicone, and metal salts (
silica and alumina sols, aluminum isopropoxide, monoaluminium phosphate and other phosphates, respectively). Table I below shows specific forms of these precursors.

table ! Ceramic 1Iij Precursor According to the method of the present invention, a discontinuous material consisting of ceramic particles, a ceramic precursor, and optionally a binder is dispersed in a liquid to form a matrix mixture slurry. As used herein, the term "discontinuous material" shall mean powders, particles, small pieces, nodules of material, whiskers, and the like. The characteristics of this slurry liquid are that it contains a ceramic precursor and a. When using a binding material, a binding shrine,! : I11 soluble, preferably 11. (is that it is a solvent for it.

This results in a 7-trix mixture in which the precursor is substantially uniformly distributed in the slurry together with the ceramic particles and the optional binder.

This liquid can be organic, which can also be aqueous, for example, depending on the precursor or its mixture and the bonds H, if present. As already mentioned, the precursor is preferably dissolved in this liquid, in which case this liquid acts as a solvent. Typical organic liquids used as solvents17 include ethyl alcohol, trichloroethane, methyl alcohol, toluene, and methyl ethyl alcohol, which can keep the binder, polymer, and/or infiltrant in solution. The amount of solvent required depends on the solubility and saturation limit of the binder phase/polymer and the desired viscosity of the slurry. Preferably the solvent is 20
-30% by weight. Any further increase in solvent content ε will only increase the drying time required to evaporate the excess solvent.

With respect to the ceramic particles in the slurry, such particles are present at a ratio of 1:1 to the sum of the ceramic particles and precursor. te 40
It is recognized that it should be included in a range of greater than 90% by weight. If it is less than 40% by weight, there will be insufficient ceramics to form a 7 trix around the reinforcing fibers in the composite part H, and the pores will become too large. about 9
If the color exceeds 0% by weight, the ceramic phase of the precursor after the change results in insufficient bonding of the ceramic particles around the reinforcing fibers. Preference of Ceramic Particles for Accounting of Particle Precursors 1. The range is 50 = 80%, especially about 70%
-80% by weight.

To obtain proper flowability and bonding, the ceramic precursor should be included in the matrix mixture slurry in a range of about 10-40% by weight of the precursor and ceramic particles, with 10-30% by weight. It is recognized that ε is preferred. If the amount is less than about 10% by weight, there will be insufficient bonding with the ceramic particles after heating which causes fluidization of the ceramic phase and precursor decomposition. Above about 40% by weight, too many pores will be created within the matrix phase due to decomposition of the precursor.

The remainder of this slurry is mostly liquid. However, other substances such as binders, plasticizers, etc. (generally referred to herein as ``binders'') are used to hold the uncured 7trix in place. may also be included in the slurry. The binder to keep the foam above 1-♀ before heating to processing temperature is about 20% of the total of ceramic particles, precursor and binder.
It can contain up to % of market weight. If the amount is more than this, there will be too many pores. Examples of (commercially available) binders and plasticizers evaluated include Prestoline Master Mix [P
r5stallne Master MIK, P, B, S, ChelIlica
l)], cellulose ether [Dow Chemical
Chemical)], polyvinyl butyral and butylbenzyl phthalate [both Senzant (Mons
anto)], and polyalkylene glycols and polyethylene glycols [Union Carbida]. Similarly, the bonding systems used were epoxy resins, such as general purpose epoxy resins from C1ba-Gelgy, silicones, such as polysiloxanes [GE
)],' RTV [GE] and polycarbosilane [Union Carbide
Carbfde]. Optionally, dispersants such as glycerol trioleate, fish oil, adipic polyester, sodium polyacrylate, phosphate ester, and the like were included. When an epoxy resin was used as a bonding system with the preferred range of precursors and ceramics described above, the epoxy amounted to about 1-10% by weight of the mixture of precursor and ceramic particles.

In connection with the present invention, various fibers were evaluated, including ceramic reinforcing fibers shown together with their coefficients of thermal expansion (CTE) in Table 1 below.

Table ■ Reinforcing Fibers In Example 1 evaluated in connection with the present invention, the matrix mixture slurry contained ceramic particles of about 0.2 to
It contained Al2O3 particles in the 50 micron size range, a silicone commercially available as RTV as the ceramic precursor, and an epoxy resin coated as bisphenol as the binder. This typical mixture contains 70-80% by weight A 120 a, based on the sum of Al2O3, silicone and binder;
Silicone is 10-30% by weight and epoxy is 1-30% by weight.
It was 10% by weight. This mixture, as a liquid,
The matrix mixture slurry was combined with a mixed solvent of trichloroethane and ethanol in an amount of ~30% by weight.

The remainder of the slurry, 70-80% by weight, was the above mixture of ceramic, precursor and binder.

Example 2 included a combination of ceramic precursors. Such a mixture contains 70-80% by weight Al2O3 based on the sum of ceramic particles, precursor and binder.
as ceramic particles, 5-15% by weight of silicone, 5-15% by weight of aluminum isopropoxide as a ceramic precursor, and an amount of 1-10% by weight of epoxy as a binder. This mixture was combined with a mixed solvent of trichloroethane and ethanol in an amount of about 20-30% by weight as a liquid to form a matrix mixture slurry. 70 to 80, which is the remainder of this slurry.
The weight percent was the above mixture of ceramic, precursor and binder.

In one embodiment of the method of the present invention, each of the matrix mixture slurries of Examples 1 and 2 above was spooled around reinforcing ceramic fibers in the form of a woven fabric. In these examples, the reinforcing fibers are Sumjto fibers identified above.
IIlo) yarns or rovings and included in the range of 20-40% by volume of the part. In other embodiments and examples, the reinforcing ceramic fibers were wound filaments. In the present invention, the reinforcing fibers are about 10% of the material.
It should be included in the range of ~50% by volume, and 30-40%
It has been found that % by volume is preferred. If it is less than 10% by volume, the reinforcing strength will be insufficient, and if it is more than about 50% by volume, the fibers will become too dense and the matrix will not be properly distributed between them.

After drying this prepreg and evaporating most of the solvent, the resulting prepreg layer is subjected to a process known and practiced in the industry, such as an autoclave. Use 1. Part 1 is shaped and molded by applying temperature and pressure. ``[Also. After that, this member is cooled into a solid preform shape (2).

Next, this puri-no-form is heated to a processing temperature in the range of 6 O0-=10 O0℃! ,,,, 7-0 This warm vagina is,
The generally much higher sintering 2,1λ used in the known method
(for example, in the range of about 1300 to 1650°C)
Very low. The second heating is performed to remove and decompose organic materials such as organic binders and to transform the receramic precursor into a ceramic binder. Practicing the present invention using a binder precursor containing ceramic particles reduces the heating temperature to a range well below the processing temperature required to sinter the ceramic particles around the reinforcing fibers. can be held.Also,
In cases other than the present invention, it is possible to use fibers that deteriorate or are thermochemically damaged at known high sintering temperatures.

In Examples 1 and 2 above, the heating at the processing temperature was approximately 600-
- Testing was carried out at a temperature of 800°C. This kind of addition, J,! 1
As a result, the ceramic particles are bonded to each other through the ceramic phase. , , 7: A ceramic matrix is obtained. Generally, this matrix has an open porosity of about 5 to
It's in the range of 30%.

In yet another aspect, the present invention includes the additional step of reducing or eliminating porosity as described above. In such embodiments, another precursor in liquid form or dispersed in a liquid, usually at high concentration, is used.11. to infiltrate into the pores of the ceramic matrix. If necessary, immerse the matrix in a liquid ceramic precursor infiltration barrier/j21. , it is possible to make it easier for the molten F5/phase to permeate into the pores. After drying, the infiltrated matrix is heated 17 to remove some porosity by converting the infiltrant ceramic precursor into a ceramic phase. Such pore infiltration and transforming heating can be repeated as desired to reduce or eliminate the porosity of the matrix to a desired degree.

The comparison graph in FIG. 1 is a stress strain curve showing the fracture resistance and toughness of a member prepared according to the present invention.

The data in Figure 1 was obtained from tests at room temperature. The specimen used was 0.5'X6'XQ.

It was a 1' rectangular test frame.

The data shown for curve IT was prepared as described above from the mixture of Example 1 above. These are the test results for the sample. However, in this case, the slurry was not dispersed around the reinforcing fibers. The material of curve 1 is a simple, stiff matrix of ceramic particles, ceramic precursors and J-boxy binders, which has low strength and rapidly undergoes brittle fracture. This type of tit a ceramic is not a candidate for critical geometries in flat applications due to its lack of tolerance to defects and resulting low toughness.

The data represented by curve 2 in FIG. 1 was obtained by testing a specimen of the same size ε and shape made from the same mixture as the specimen used to obtain the data of curve 1. In this case, the mixture was sprinkled and dispersed in an amount of about 30% by volume based on the component on a reinforcing rope fabric made of Sumitomo (Su+++jtom0) yarn.Curve 2
The material shown is a ceramic composite in which the same monotonic matrix material as in curve 1 is incorporated between and around the fiber reinforcement. This material has high strength because the load is transferred to high-strength fibers and exhibits favorable fracture behavior and toughness.

Due to this composite behavior, it is possible to create 1. It is possible for these parts to exhibit a long service life even after failure occurs.

As is apparent from FIG. 1, the reinforced ceramic matrix composite member of curve 2 has significantly higher strength and toughness than the member of curve 1.

For comparison, FIG.
Curve 3 showing a part sintered at 1500°C (twice over the usable temperature range of the fibers specified in Table ■)
This is also a list. No precursors were included in such a composite of 55% by volume aluminosilicate and 45% by volume sapphire fibers. For this reason, this mixture is at the processing temperature used in the process of the invention (generally around 600-1
It was necessary to use a sintering consolidation temperature significantly higher than 0.000°C. The curve 3 material is stronger than the curve 2 material with toughness behavior. These improved properties are the result of the use of higher strength reinforcing fibers in conjunction with a thermally compatible matrix, allowing for effective transfer of load from the matrix to the fibers.

As can be seen by comparing curve 2, which represents the present invention, with curve 3, which represents a member made using a different method, the present invention provides a reinforced material with high strength and toughness without the need for a consolidation process at extremely high temperatures. We provide ceramic composite materials that This is a result of the use of ceramic precursors in the present invention, which decompose at lower temperatures into a ceramic phase that binds the ceramic particles and reinforcing fibers together in the composite component. It is.

Typical examples of members that can be made according to the invention include:
Airfoil-shaped struts useful in the high temperature section of gas turbine engines. An example of such a strut is shown in a partially sectional perspective view in FIG. The strut, indicated generally at 10, includes a strut body 12 having a leading edge 14 and a trailing edge 16. Strut 10 is sometimes referred to as a hollow strut due to the presence of multiple cavities 18 separated by ribs 20.

Struts 10 can be made from multiple layers, such as laminations, sheets, tapes, etc. made as described above. The partial cross-sectional view of FIG. 3 is representative of schematically illustrating the arrangement of such layers. This layer consists of two layers around a forming block 24, such as aluminum.
2. This figure shows the preform shape of a portion of the strut of FIG. 2 as initially formed in relation to the shape of the final product strut. in fact,
Each layer of the member has a thickness depending on the fibers and morphology, as is well known in the industry. For example, a typical thickness is about 0.
The range is 0.008 to 0.020 inches. However, as is well known in the industry, the actual number of layers required to obtain such a laminated structure will likely be greater than that shown schematically in FIG. To reduce voids, additional individual fibers 25 are distributed between the layers within the spaces that may occur between the layers in the curved areas of the edges of the blocks 24.

After assembly around the forming block 24 to form the member of FIG. 3, this assembly is placed in a suitably shaped interlocking forming die as shown in FIG. 4 for laminating the members to form an article preform. 26A and 26B. Typically, approximately 150 to 1000 lbs.
The part is heated, for example, to a range of 150 to 400 m², while applying pressure to the part in the range of 150 to 400 m². Such temperatures do not cause compaction of these construction materials.

The preform obtained after lamination is taken out from the forming die, and the forming block is removed. This preform is then placed in a furnace and heated under controlled conditions to a temperature below 1000°C to remove binders and plasticizers, and then heated to a processing temperature above 1000°C that does not cause fiber deterioration. The preform is sintered into the substantially dense ceramic matrix composite article of FIG.

Interrelated 1989 U.S. Patent Application No. 341,001, filed concurrently with this application, the disclosure of which is hereby incorporated by reference, related to the shrinkage of ceramic particles and the resulting porosity problem. According to the invention of that related application, such shrinkage is counteracted by mixing the ceramic particles with mineral filler particles prior to consolidation. Such fillers exhibit a net expansion relative to the ceramic particles while being heated to the consolidation temperature.

Tested during the evaluation of the invention were inorganic fillers in the form of lath-type crystals specified in Table 1 below.

Fillers such as those described in Table 1 above can be used in one embodiment of the present invention to counteract porosity that occurs during heating to pressurizing temperatures. The proportion of the filler in the mixture is selected such that the expansion of the filler cancels out the pores generated.

When including the inorganic fillers of the above-mentioned related applications in the matrix mixture of the present invention containing ceramic particles and precursors and optionally binders, such filling (A is the ceramic, precursor, optionally expedient) is included. For example, the total amount of binder and filler used is approximately 50 = ?g, +1
It can be included in

The proportion of porosity is selected such that porosity is compensated for by expansion of the filler material. Such porosity may result from shrinkage of the ceramic trigonum, but as previously noted, material transformation or volume change during heating of the preforms of the present invention in an oxidizing atmosphere is likely to occur. This occurs at lower processing temperatures due to barreling.

Pores, typically composed of ceramic particles and fillers,
The joint mixture is 50-93% by weight of ceramic particles and 7-50% by weight of inorganic filler, and the pore-controlling mixture is 40% by weight of a 7-trix mixture of particles, precursors and optionally a binder. It is greater than 1 m% by weight and up to about 90% by weight.

Preferred inorganic fillers are those having a lath type crystal form as shown in Table 1 below.

In particular, pyrophillae I and wollastonite are filled with H
It turns out that it is especially suitable for q.

Also, as disclosed in the above-mentioned related application, reinforcing fibers that expand relative to the matrix mixture enhance the JJ properties of the preform at ambient temperatures.

The present invention has been described in terms of non-limiting representative embodiments and specific examples and related data. However, as will be readily apparent to those skilled in the art, the present invention is susceptible to various modifications and variations within the scope of the appended claims.

[Brief explanation of drawings]

FIG. 1 is a graph showing a comparison of fracture resistance data for an unreinforced matrix, another reinforced 7-trix, and the loss reinforcement member of the present invention. FIG. 2 is a partial cross-sectional perspective view of a portion of a gas turbine engine strut. FIG. 3 is a partial schematic cross-sectional view of a layer of ceramic matrix composite arranged around a forming block. 4 is a partial cross-sectional perspective view of the member of FIG. 3 positioned within a forming die; FIG. 10...Airfoil struts, 22...Individual layers, 24
... Forming block, 26... Forming die. Eaves, Power (ksL) Procedural Municipality 4 Eyes (Method)

Claims (20)

[Claims] (1) A ceramic matrix precursor that changes into a ceramic phase by heating, a liquid that is compatible with this precursor, and a discontinuous material consisting of ceramic particles are prepared, and the ceramic matrix precursor, liquid, and discontinuous material as described above are prepared. are mixed together to form a matrix mixture slurry having a substantially uniform distribution of ceramic particles and precursors, a plurality of oxidation-stable reinforcing fibers are provided, and the matrix mixture slurry is wrapped around the fibers. dispersed to form a prepreg preform, which is processed in an oxidizing atmosphere at a temperature above that required to transform the precursor into a ceramic phase, but below a temperature that would cause deterioration of the ceramics in the preform. Heating to a temperature transforms the ceramic matrix precursor into a ceramic phase that binds the ceramic particles from the slurry in a ceramic matrix around the fibers and is environmentally stable and fractures with high strength. A method for producing a fiber-reinforced ceramic matrix composite component, comprising obtaining a highly resistant fiber-reinforced ceramic matrix composite component. (2) the matrix mixture slurry comprises (a) 40% of the total of ceramic particles and ceramic precursor;
(b) a ceramic precursor ranging from about 10 to 40 percent by weight of said total, wherein the reinforcing fibers account for about 10 to 50 percent by weight of said composite member; 2. The method of claim 1, wherein the amount is % by volume. (3) The method according to claim 2, wherein the reinforcing fibers are ceramic fibers. 4. The method of claim 2, wherein the prepreg preform is heated in air at a processing temperature in the range of about 600-1000<0>C. 5. The method of claim 2, wherein a binder is provided and included in the slurry in an amount up to about 20% by weight of the total of ceramic particles, ceramic precursor, and binder. (6) The matrix mixture slurry contains ceramic particles, ceramic precursors, and binders in a total of 70 to 80% by weight (of which, ceramic particles are 50 to 80% by weight, and ceramic precursors are 10 to 30% by weight). , binder (1 to 20% by weight of the total), and 20 to 30% by weight of a liquid as an organic liquid. (7) Ceramic precursor is an organometallic compound, sol-gel,
A material selected from the group consisting of metal salts and mixtures thereof, in which the ceramic particles contain Al, Si, Ca,
3. The method of claim 2, comprising a material selected from the group consisting of oxides of Hf, B, Ti, Hf, Y and Zr and mixtures and combinations thereof. 8. The method of claim 1, wherein the plurality of fibers are in the form of a layer and the matrix mixture is spread around the fibers in this layer to obtain the prepreg layer. (9) The method according to claim 8, wherein a plurality of prepreg layers are laminated to form a prepreg preform before heating. (10) Ceramic infiltration into the open structures in the part after heating the preform in an oxidizing atmosphere to transform the ceramic matrix precursor into a ceramic phase to create a denser composite part. 2. The method of claim 1, further comprising contacting the composite member with the infiltrant precursor and then heating the infiltrated member in an oxidizing atmosphere to transform the infiltrated ceramic infiltrant precursor into a ceramic phase. (11) The matrix mixture slurry also contains, in addition to the ceramic particles, a particulate inorganic filler that exhibits a net expansion relative to the ceramic particles when heated to the processing temperature, and the proportion of the inorganic filler in the matrix mixture 2. The method of claim 1, wherein the filler is selected such that expansion of the filler counteracts porosity that occurs in the preform during heating to the processing temperature. (12) the matrix mixture slurry includes a binder, wherein: (a) greater than about 40% by weight of the sum of the ceramic particles, ceramic precursor, inorganic binder, and filler;
(b) ceramic precursors ranging from about 10 to 40% by weight of said total; (c)
12. The method of claim 11, comprising: a) a binder in a range of up to about 20% by weight of said total; and (d) an inorganic filler in a range of up to about 50% by weight of said total. (13) (a) The ceramic particles are about 50 to 8 of the above total.
(b) the ceramic precursor is in the range of about 10-30% by weight of said total; (c) the binder is in the range of about 1-20% by weight of said total; and (d
13.) The method of claim 12, wherein the inorganic filler ranges from about 7 to 50% by weight of the total. (14) A ceramic matrix consisting of a plurality of reinforcing fibers, ceramic particles scattered around the reinforcing fibers, and a ceramic binder phase that binds the ceramic particles and reinforcing fibers together. Fiber-reinforced composite components with improved durability, combining improved high strength with high fracture resistance. 15. The member of claim 14, wherein the reinforcing fibers are about 10-50% by volume of the member. 16. The component of claim 14, wherein a plurality of layers of ceramic bonded ceramic particles and reinforcing fibers are bonded together. 17. The component of claim 14, wherein the reinforcing fibers are ceramics, thereby defining a ceramic fiber-reinforced ceramic matrix composite component. (18) Claim 1, wherein the ceramic matrix contains an inorganic filler having a lath type crystal form.
4. The member described in 4. (19) The ceramic particles range from about 7 to 50% by weight of the total of the ceramic particles and the ceramic binder phase, the ceramic binder phase ranges from about 1 to 20% by weight of the total, and the reinforcing fibers 15. The member of claim 14, wherein: is in the range of about 10-50% by volume of the member. 20. The component of claim 19, wherein the inorganic filler having a lath-type crystalline form is included in an amount ranging from about 7 to 50% by weight of the total of the ceramic particles, ceramic binder phase, and filler.