MXPA98001317A - Multiple ceramic reinforced with ceramic fiber, coated with me - Google Patents

Abstract

This invention relates to parts of an internal combustion engine or the like and, more particularly, to an exhaust manifold of reinforced ceramic matrix composite (10) for applications of internal combustion engines. The present invention solves the problems of failure due to thermal shock, damage by minor impacts, erosion, weight of the motor and the like. A method for making the exhaust manifold (10) comprises the steps of forming a liner of a monolithic cast ceramic material containing pores, filling the pores with a pre-ceramic polymer resin, coating the reinforcing fibers with a contact surface material, form a mixture of a pre-ceramic polymer resin and reinforce the coated fibers with the contact surface material, form a configured multiple exhaust structure from the mixture by placing the mixture over less a portion of the casting material, and ignite the structure, thus forming a composite ceramic material reinforces

Description

MULTIPLE OF CERAMIC REINFORCED WITH CERAMIC FIBER- COATED WITH METAL- TECHNICAL FIELD This invention relates to an internal combustion engine or the like, and more particularly, to an apparatus for channeling the exhaust emissions of an internal combustion engine, comprising: a plurality of collecting pipes connected to and receiving exhaust gases from the plurality of engine exhaust ports; and an outlet thereof connected to an exhaust pipe. More specifically, the invention relates to an exhaust manifold composed of ceramic matrix reinforced with structural fiber, low heat rejection, corrosion resistant, high temperature resistant, and rupture resistant, for engine applications of internal combustion.

BACKGROUND OF THE INVENTION For many years, the exhaust systems of internal combustion engines have remained substantially unchanged. There is a metal exhaust manifold, typically cast with iron or steel, or tubular steel, which collects the exhaust gases emitted from the exhaust ports of the engine and exhausts them into an individual exhaust pipe. Typically, a muffler, and / or a catalytic converter device is arranged in line with the exhaust pipe to reduce noise and contaminants associated with the operation of the engine. A typical prior art multiple exhaust design is presented in simplified form in Figure 1, where it is generally indicated as 10. There are a plurality of flanges, which are bolted or fastened over the exhaust ports (not shown) of the engine (not shown). The flanges connect individual collector pipes 14 to a common outlet pipe 16 which leads and is connected to the exhaust system (not shown) at 18. Since a good exhaust gas flow (minimum restriction) is important in the total operation of the engine, the curves of the pipes, the interior softness, and the like, are factors considered by its designers. Such factors are somewhat relevant to the novelty of the present invention, but will not be addressed herein in favor of the simplified drawings, which clearly indicate the true novelty in a form easily understood by those skilled in the art. The exhaust manifolds, very old and of the prior art, were totally made of metal as indicated in Figure 2. The commercial manifolds were / are generally of cast iron or molten steel, while the specialty manifolds for high performance engines and similar, were / are welded steel or stainless steel pipe in order to provide a "tuned" exhaust as is known to those skilled in the art. Engine designers continue to struggle with the current exhaust manifolds of metal design in two different areas. First, during the operation of the heavy load motor, the engine gases can be in an excess of 760 ° C, while the engine block that is mechanically connected to it is maintained at a maximum of 148.8 ° C by a water cooling system. If a cast iron exhaust manifold is allowed to become too hot, the manifold can twist or even crack at the large loads introduced therefrom from the large differences in thermal expansion between the two mechanically connected parts. This is due to its high temperature. The manifolds wish to thermally develop a much larger size than the mechanical connection connected to the block will allow. This failure allows the starting exhaust gases to go into the engine compartment. This occurrence typically requires the replacement of, or the removal and repair of the manifold. Although not a well-known problem, those experts in the technical field of engine design will agree that it is a continuous dilemma. The aspects of current technology to mitigate the problem are to use a much higher cost stainless steel, which has a substantially lower coefficient of thermal expansion than the cast iron, or reduce the total temperature of the exhaust manifold by increasing the heat rejected back to the block in the mounting flanges, or segment the exhaust manifold into sections that are they slide one inside the other in order to provide the multiple with the capacity for growth. Segmented exhaust manifolds, however, tend to leak out at joints, over time. The second point of difficulty for motor designers is presented mainly in the marine industry. Here, the regulation requirements dictate maximum permissible engine compartment temperatures and engine "touch" temperatures for indoor marine applications. This typically requires the use of multiple exhaust cooled with water to obtain the regulation restrictions. The main problem associated with this aspect is the corrosion of the metal manifold. As a result, water-cooled cast iron manifolds must be replaced much more frequently than desirable; or, the manifolds must be manufactured from a much more expensive stainless steel material. More recently, for use with motors having higher operating temperatures, it has been suggested to add a ceramic liner 20, as shown in Figure 3. For this, the prior art only suggests the use of a monolithic ceramic material. . See, for example, the Ford Motor Company patent of Hartsock with reference of 1995 (5,404,721). Up to now, it is an object of the present invention to provide said exhaust manifold made entirely of a composite material of structural fiber reinforced ceramic matrix (FRCMC).

Other objects and benefits of this invention will be apparent from the description presented below, when read together with accompanying drawings that accompany it.

DESCRIPTION OF THE INVENTION The above objects have been achieved in an exhaust manifold for an internal combustion engine having a plurality of collector pipes that will be connected to and receive exhaust gases from the respective pipes of a plurality of engine exhaust ports and an individual outlet to the engine. which will be connected to a pipe or exhaust system, wherein the exhaust manifold is a composite material of ceramic matrix reinforced with structural fiber comprising fibers of a generic fiber system, which have been coated with a surface material of generic contact arranged through a ceramic matrix. The preferred resin for creating the ceramic matrix is either of the two polymer-based ceramic resins comprising silicon-carboxyl and alumina silicate, or a cementitious resin that has been modified to emulate the processing methods of the composite systems of typical structural polymer such as monoaluminum phosphate resin (also known as monoaluminum phosphate). The preferred generic fiber system comprises alumina, Altex, Nextel 312, Nextel 440, Nextel 550, silicon nitride, silicon carbide, HPZ, graphite, carbon and peat. The preferred generic contact surface material comprises carbon, silicon nitride, silicon carboxyl, silicon carbide or boron nitride, or a layered combination of one or more of the above contact surface materials. In another co-pending application entitled METHODS AND APPARATUS FOR MAKING CERAMIC MATRIX COMPOSITE LINED AUTOMOTIVE PARTS AND FIBER REINFORCED CERAMIC MATRIX COMPOSITE AUTOMOTIVE PARTS, by the inventors of the present serial number PCT / US96 / 11772, filed on the same date as this , a composite ceramic matrix reinforced with reinforced structural fiber (FRCMC) material is described for lining metal parts such as exhaust manifolds, which do not present the problems of failure due to thermal shock, damage by minor impacts, or erosion of a monolithic ceramic liner. A first aspect is a method for forming a metal part having a rupture-resistant ceramic liner comprising the steps of forming a metal part having a matched surface to receive the liner, forming a lining of a material of ceramic containing pores; fill the pores with a pre-ceramic resin; igniting the liner saturated with pre-ceramic polymer resin at a temperature and for a time (designated by the resin manufacturer), which converts the resin to a ceramic within the pores; and, join the ceramic lining to the surface matching the surface of the metal part. In one embodiment, the step of forming the lining of a pore-containing ceramic material comprises emptying an inexpensive meltable cementitious slurry into a liner-shaped mold, igniting the molded mud material for a time and at a temperature that makes it to a manageable pre-ceramic form, remove the pre-ceramic form from the mold, and ignite the pre-ceramic form for a time and at a temperature that converts it to a ceramic form containing pores formed by degassing. And, the step of filling the pores with a polymer-derived ceramic resin comprises placing the liner in a bath containing a liquid pre-ceramic polymer resin until the pores become saturated with resin. Preferably, the resin is a silicon-carboxyl resin (sold by Allien-Signal under the trade name of Blackglas). In a second embodiment, the step of forming the lining of a ceramic material containing pores comprises placing a fiber preform in a liner-shaped mold to occupy 30% to 60% of the mold, forcing a pre-ceramic liquid polymer resin through the preform to fill the remaining volume of the mold with the resin of the liquid pre-ceramic polymer, igniting the mold for a time and at a temperature which makes it a pre-liquid form. manageable ceramic, remove the pre-ceramic shapes from the mold, and ignite the pre-ceramic shape for a time and at a temperature that converts the liquid pre-ceramic polymer resin to a composite form of ceramic matrix containing pores formed by degassing. Preferably, the liquid pre-ceramic polymer resin is a silicon carboxyl resin, for example Blackglas. A second aspect of the present invention is a method for forming a metal part having a rupture-resistant ceramic liner comprising the steps of forming a lining of a ceramic material containing pores.; fill the pores with a pre-ceramic resin; igniting the liner saturated with pre-ceramic resin at a temperature and for a time (as designated by the resin manufacturer), which converts the resin to a ceramic within the pores; placing the liner inside a mold for the metal part with the matching surface of the liner facing towards a portion of the mold that will be occupied by the metal that forms the part; and fill the mold with the molten metal to form the part. As with the first aspect, the step of forming the liner of a ceramic material containing pores can comprise any of the aforementioned aspects. And, the step of filling the pores with a polymer-derived resin again comprises placing the liner in a bath containing a liquid pre-ceramic polymer resin until the pores become saturated with resin; ignite the liner saturated with pre-ceramic polymer resin at a temperature and for a time that converts the resin to a ceramic within the pores. In all cases where the pores formed by degassing are filled, it is preferred to repeat the pore filling and reheating procedure several times to virtually and completely remove the pores of the final product. In another aspect of the present invention, a method for making an automotive part composed of fiber reinforced ceramic matrix, comprising the steps of forming a preform in the part configuration from a generic fiber system that it can be used in fiber-reinforced ceramic matrix composite materials; placing the preform in a cavity of a mold having the shape of the part; forcing a ceramic resin derived from liquid polymer through the cavity to fill the cavity and saturate the preform; heating the mold at a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the saturated preform with ceramic resin derived from liquid polymer to a polymer composite part; remove the polymer composite part of the mold; and igniting the polymer composite part in an inert atmosphere at a temperature and for a time associated with the polymer-derived resin, which transforms the polymer-derived ceramic resin into a resin, whereby the polymer composite part is converted to a polymer resin. a composite part of ceramic matrix reinforced with fiber. Preferably, the method also includes the steps of submerging the composite part of fiber-reinforced ceramic matrix containing the pores formed by degassing during ignition, in a bath of the polymer resin derived from liquid polymer to fill the pores with the ceramic resin derived from liquid polymer; igniting the composite part of fiber-reinforced ceramic matrix in an inert atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the polymer-derived ceramic resin into the pores to the ceramic; and, repeating this procedure until the pore density within the composite part of the final fiber reinforced ceramic matrix is less than a preset percentage offering maximum strength to the part. The preferred method can also be adapted to form hollow parts such as motor manifolds using the steps of forming a first preform in the configuration of a first lower portion of the manifold from a generic fiber system that can be employed in composite materials ceramic matrix reinforced with fiber; placing the first preform in a cavity of a first mold having the shape of the lower portion of the manifold; forcing a ceramic resin derived from liquid polymer through the cavity to fill and saturate the first preform; heating the first mold at a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the first preform saturated with ceramic resin derived from liquid polymer to a first polymer composite part; remove the first polymer composite part of the mold; forming a second preform in the configuration of an upper portion of the manifold from the generic fiber system; placing the second preform in a cavity of a second mold having the shape of the upper portion of the manifold; forcing the resin derived from liquid polymer through the cavity to fill and saturate the second preform; heating the second mold at a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the second preform saturated with resin derived from liquid polymer to a second part composed of polymer; remove the second polymer part from the mold; fixing the first polymer composite part and the second polymer composite part together along matching edges to form the manifold as a hollow duct-shaped part; and, igniting the multiple polymer composite in an inert atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the polymer-derived resin into a ceramic, whereby the multiple polymer compound is transformed to a fiber reformed ceramic matrix manifold and the upper portion and the lower portion are fused together along the coincident edges. Preferably, the pores formed by degassing are sealed in the manner described above to give maximum resistance to the resulting manifold and seal any leakage that may exist along the mating edges. When the manifold is an exhaust manifold that will be filled internally with a ceramic foam catalyst substrate structure, the procedure and the required tool can be greatly simplified before the step of placing the second preform into a cavity of a second mold which has the shape of the upper portion of the manifold; also including the steps of, placing the first preform as part of a wall defining a cavity of the second mold; and, placing the ceramic foam catalyst substrate structure in the first preform, whereby the first preform and the ceramic foam catalyst substrate structure in combination form part of the cavity of the second wall. In this way, in the interest of the weight of the motor, and the like, an exhaust manifold entirely of ceramic material could be highly desirable.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a simplified plan view of a typical exhaust manifold structure. Figure 2 is a cross-sectional view through the exhaust manifold of Figure 1 in the plane ll / III / IV-ll / III / IV, when the manifold is a metal manifold of the prior art.

Figure 3 is a cross-section through an exhaust manifold of Figure 1 in the plane ll / III / IV-ll / III / IV, when the manifold is a metal manifold of the prior art having a liner of monolithic ceramics on its internal walls. Figure 4 is a cross section through the exhaust manifold of Figure 1 in the ll / III / IV-ll / III / IV plane, when the manifold is a FRCMC manifold according to the present invention. Figure 5 is a partially cut-away drawing of a mold showing how the FRCMC manifold of the present invention can have additional structural metal members attached thereto by molding them in place.

BEST MODE FOR CARRYING OUT THE INVENTION In accordance with the present invention, and also as employed in the aforementioned engine, the exhaust manifold 10 'of Figure 4 is made entirely of a FRCMC structure, which eliminates intolerance to stress and notch sensitivity of the conventional monolithic ceramic structures of the prior art. The FRCMC of this invention employs any of the polymer-derived resin (formerly used interchangeably with the term commercially available pre-ceramic polymer resin), such as the silicon-carboxyl resin (sold by Allied-Signal under the name commercial Blackglas), alumina silicate resin (sold by Applied Poleramics under the trade name of C02), or cement systems that have been modified to emulate typical structural polymer composite system processing methods such as phosphate resin monoaluminum (aka monoaluminum phosphate) resin combined with a generic fiber system (hereinafter interchangeably used with the term reinforced fibers), such as, but not limited to alumina, Altex Nextel 312, Nextel 440, Nextel 510, Nextel 550 , silicon nitride, silicon carbide, HPZ, graphite, coal and peat. To achieve the objects of the present invention, the fiber system is first coated to a thickness of 0.1 to 5.0 microns with a contact surface material, but not limited to, carbon, silicon nitride, silicon-carboxyl, silicon carbide. or boron nitride. The material of the contact surface prevents the resin from adhering directly to the fibers of the fiber system. In this way, when the resin has been converted to a ceramic, there is a weak separation layer between the ceramic and the fibers imparting the desired qualities more ductile to the final FRCMC. Thus, in accordance with the present invention, the steps of constructing a ceramic exhaust manifold, of low heat rejection, corrosion resistant, rupture resistant, comprise applying the contact surface material on the system of fibers as the best standards in the industry, mix the coated fiber system with the contact surface with the resin, form the multiple as the best industry practice used in the manufacture of structural polymer composite hardware, and turn on the resulting part at a high temperature by specifications of the supplier of the material to convert the resin into a ceramic. There are a number of distinct advantages offered by an FRCMC internal combustion engine exhaust manifold over multiple monolithic metal ceramics and current potentials and they are as follows: 1) Since the manifold is a ceramic, it inherently has an insulating capability better than its metallic counterpart, thus reducing the thermal load of the engine compartment. 2) Since the manifold is a ceramic, has a substantially lower coefficient of thermal expansion than its metallic counterpart, thus reducing the thermally induced loads on the manifold from the upper extreme temperature differential between the engine block and the manifold. 3) Since the manifold is a ceramic, it is inherently resistant to corrosion. 4) Since the manifold is a ceramic, it is inherently more resistant to temperature than its metallic counterpart. 5) Since the manifold is a ceramic, it is inherently in substantial form lighter than its metallic counterpart (FRCMC is of lower density than aluminum, ie, approximately 2.2143 g / cm). 6) Since the manifold is a fiber reinforced composite material with a fiber contact surface coating, it is substantially more tensile tolerant (ductile) than its monolithic ceramic counterpart. 7) Since the manifold is a fiber reinforced composite material with a fiber contact surface coating, it is substantially less sensitive to grooving than its monolithic ceramic counterpart. 8) Since the manifold is a fiber reinforced composite material with an adjoining fiber surface coating, it is substantially more resistant to breakage than its monolithic ceramic counterpart. 9) Since the manifold is a fiber reinforced composite material with a fiber contact surface coating, its strength characteristics can be designed through fiber selection, contact surface coating and fiber orientation. 10) Since the manifold is a fiber reinforced composite material, with a fiber contact surface coating, its coefficient of thermal expansion can be designed to better match that of the engine block through fiber system selection. 11) Since the manifold is a fiber-reinforced ceramic matrix composite with a fiber contact surface coating, its material properties do not degrade as a function of temperature on the manifold operating temperature scale as makes its metallic counterpart. 12) Since the manifold is a fiber-reinforced ceramic matrix composite with a fiber contact surface coating, it is much more resistant to the damage that results from thermal shock than its monolithic ceramic counterpart.

Example: FRCMC Exhaust manifold fabrication 1. Deposit a pair of multiple halves (top and bottom halves) that will be joined in a final step or a total multiple of a mat of non-woven fabric fibers, such as, but not limited to a, Altex alumina, Nextel 312, Nextel 440, Nextel 510, Nextel 550, silicon nitride, silicon carbide, HPZ, graphite, carbon and peat. 2. Multi-part halves or full-multiple fiber preform, then a fiber contact surface coating is applied as the best industry practices. The fiber could have been coated before the formation of the fiber manifold configurations. The assignee of this application, Northrop Corporation, currently has a number of patents in the contact surface coating application, including U.S. Patent No. 5,034,181, entitled APPARATUS FOR METHOD OF MANUFACTURING PREFORMS; U.S. Patent No. 5,110,771, entitled METHOD OF FORMING A PRECRACKED FIBER COATING FOR TOUGHENING CERAMIC FIBER-MATRIX COMPOSITES; U.S. Patent No. 5,275,984, entitled FIBER COATING OF UNBONDED MULTI-LAYERS FOR TOUGHING CERAMIC FIBER-MATRIX COMPOSITES; United States Patent No. 5,162,271, entitled METHOD OF FORMING A DUCTILE FIBER COATING FOR TOUGHENING NON-OXIDE CERAMIC MATRIX COMPOSITES: US Patent No. 5,221,578, entitled WEAK FRANGIBLE FIBER COATING WITH UNFILLED PORES FOR TOUGHENING CERAMIC FIBER -MATRIX COMPOSITES, the teachings of which are incorporated here for reference. Also, Allied-Signal or Sinterials are commercial companies, which will apply a contact surface coating as a purchase service. 3. The multiple halves or the complete manifold, are then saturated with the resin, in this example, being a Blackglas resin. This step may also include the compression of the mixture of the polymer-derived ceramic resin and the fibers coated with the contact surface material of a generic fiber system under pressure in a mold to form the multiple-shaped structure. 4. The multiple halves saturated with resin or the complete manifold is then heated by the following cycle: A) Ambient ramp at 65.5 ° C at 2.7 ° / minute B) Keep at 65.5 ° C for 30 minutes C) Ramp at 1.7 ° / minute at 148.8 ° CD) Hold at 148.8 ° C for 60 minutes E) Cool it 1.2 ° / minutes until the temperature is below 60 ° C. It should be noted that there is a variety of definitions of heating cycles which will create a usable product and the foregoing is by way of example only and is not intended to be exclusive. 5. They are made of multiple halves, then they are fixed together along coinciding edges at this point to form a total manifold. The two pieces now fixed together are immersed in the Blackglas resin for a minimum of 5 minutes. The part is then removed from the resin and heated as the previous ramp rate to hold the edges together. 6. The polymer composite material manifold is then pyrolyzed. In this regard, the manufacture of a sealable container, such as a stainless steel box, capable of withstanding a temperature of 1037.7 ° C is required for the pyrolysis cycle in a normal furnace. In the alternative, if available, an inert gas oven can be used. The box must have two pipe connections, one on the bottom and one on the top, to allow the box to be flooded with an inert gas.

In this example, the manifold is placed in the box, the box placed in a normal oven, the stainless steel pipe is connected to the bottom connector of the box and a supply of high purity argon. Of course, any equivalent inert gas can be used. The argon is allowed to flow into the box, and exits in the upper vent at a rate of 141.58-283.16 liters per hour for the total heating cycle, thus ensuring that the multiple is totally involved in an inert environment. The furnace is closed and ignited with the following base: A) Ramp at 148.8 ° C at 223 ° C / hour B) Ramp at 482.2 ° C at 43 ° C / hour C) Ramp at 760 ° C at 20 ° C / hour D) Ramp at 871 ° C at 50 ° C / hour E) Keep at 871.1 ° C for 4 hours F) Ramp at 25 ° C at -125 ° C / hour Again, there is a variety of heating schedules different from this, given in a manner for example only, which will produce usable hardware. 7. After cooling, the manifold is removed from the furnace and box and immersed in a Blackglas resin bath for a sufficient time to allow all air to be removed from the manifold (typically 5 minutes or more). You can also use a step of vacuum infiltration for this step. This fills any pore caused by degassing or shrinking of the matrix in the FRCMC manifold with the resin. 8. Steps 6 and 7 are then repeated until the porosity level is below a desired level, which imparts maximum resistance to the final FRCMC manifold.

Typically, it is preferred that this cycle be repeated five times. The manifold is then ready to be used. Figure 5 depicts an alternative aspect of the present invention, which may be employed, if desired, to increase the strength of the resultant manifold. Since it is a ceramic material, the multiple 10 'can be subjected to molten metal without damage. In this way, a basic manifold 10 'can be made as described above, which does not have completed tabs 12, for example. As shown in Figure 5, the basic manifold 10 'is then placed inside a mold 22. The molten metal 24 is then emptied into the mold 22. The metal 24 flows around the enclosed portions of the manifold 10' of FRCMC capturing them within the metal as it hardens, thereby forming the tabs 12 and / or, if desired, a strong system 26, which can be attached by bolting the automobile to support the manifold 10 'against the bending forces Excessive exhaust system, and the like.

Claims (43)

1. A method for making an exhaust manifold composed of fiber reinforced ceramic matrix, resistant to high temperature, for a motor, comprising the steps of a) forming a liner of a monolithic, castable ceramic material containing pores; b) filling the pores of the monolithic casting ceramic material with a pre-ceramic polymer resin; c) coating the reinforcing fibers with a contact surface material to prevent the pre-ceramic polymer resin from adhering strongly to the reinforcing fibers; d) forming a mixture of a pre-ceramic polymer resin and reinforcing fibers coated with the contact surface material, e) forming a configured exhaust manifold structure from the mixture of the polymer resin of ceramic and the reinforcing fibers coated with the contact surface material, placing the mixture in at least a portion of the monolithic casting ceramic material, and f) igniting the configured structure of the exhaust component at a temperature and for a sufficient time to convert the pre-ceramic polymer resin to a ceramic, thus forming a reinforced ceramic composite material.

2. The method according to claim 1, wherein the step of coating the reinforcing fibers with a contact surface material comprises: coating the reinforcing fibers with a thickness of 0.1 to 5.0 microns of at least one layer of the material of contact surface of at least one of carbon, silicon nitride, silicon carbide, silicon carboxyl, or boron nitride.

The method according to claim 1, wherein the step of coating the reinforcing fibers with a contact surface material comprises: coating the reinforcing fibers of at least one of alumina, high purity alumina, silicate alumina-boron, molita, alumina silicate, silicon nitride, silicon carbide, carbon, or peat with the contact surface material.

The method according to claim 1, wherein the step of forming a mixture of the resin of the pre-ceramic polymer and the reinforcing fibers coated with the contact surface material comprises: mixing the coated reinforcing fibers with the contact surface material with a material selected from the group consisting of commercially available pre-ceramic polymer resins such as silicon-carboxyl resin, aluminum silicate resin or monoaluminium phosphate resin.

The method according to claim 1, wherein the step of forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and reinforcing fibers coated with the contact surface material , comprises: compressing the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material under a pressure in a mold to form the multi-configured structure before ignition.

The method according to claim 1, and, after step (f) thereof, further igniting comprises the steps of: a) placing the ceramic manifold in a mold; and b) pouring molten metal into the mold around the portions of the ceramic manifold to add the structural components of the metal to the ceramic manifold.

7. A method for making an exhaust manifold of fiber-reinforced ceramic matrix material, resistant to high temperature, for an engine, comprising the steps of: a) forming a lining of a monolithic casting ceramic material that contains pores; b) filling the pores of the monolithic casting ceramic material with a pre-ceramic polymer resin; c) coating the reinforcing fibers with a contact surface material to prevent a pre-ceramic polymer resin from adhering directly to the reinforcing fibers, reinforcing fibers comprising fibers from at least one of alumina, alumina high purity, alumina-boron silicate, mulite, alumina silicate, silicon nitride, silicon carbide, HPZ, graphite, carbon, or peat, the contact surface material comprising a thickness of a few microns of at least one of carbon, silicon nitride, silicon carbide, silicon carboxyl, or boron nitride; d) forming a mixture of a pre-ceramic polymer resin selected from the group consisting of silicon-carboxyl resin, monoaluminium phosphate resin, or alumina silicate resin and the reinforcing fibers coated with the surface material contact; e) forming an exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material by placing the mixture in at least a portion of the monolithic ceramic material of casting; and, f) igniting the configured manifold manifold structure at a temperature and for a time sufficient to convert the pre-ceramic polymer resin to a ceramic, thereby forming a reinforced ceramic composite material.

The method according to claim 7 wherein the step of forming a mixture of a pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material, comprises: saturating a mat of the fibers of woven fabric reinforcement coated with the contact surface material and the pre-ceramic polymer resin.

The method according to claim 8 wherein the step of forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material further includes the step of: compressing the mat of the reinforcing fibers of the woven fabric coated with the contact surface material and saturated with the pre-ceramic polymer resin in a mold under pressure prior to ignition.

The method according to claim 7 and, after the ignition step (f), further comprises the steps of: a) placing the manifold in a mold; and b) pouring the molten metal into the mold around the manifold portions to add the additional structural metal compounds to the manifold.

11. A method for making an exhaust manifold of fiber-reinforced ceramic matrix material, resistant to high temperature, for an engine, comprising the steps of: a) forming a monolithic ceramic casting liner containing pores; b) filling the pores of the monolithic casting ceramic material with a pre-ceramic polymer resin; c) coating the reinforcing fibers with a contact surface material to prevent a pre-ceramic polymer resin from adhering directly to the reinforcing fibers, reinforcing fibers comprising fibers from at least one of alumina, alumina high purity, alumina-boron silicate, mulite, alumina silicate, silicon nitride, silicon carbide, HPZ, graphite, carbon or peat, the contact surface material comprising a thickness of 0.1 to 5.0 microns of at least one carbon, silicon nitride, silicon carbide, silicon carboxyl or boron nitride; d) forming a mixture of silicon-carboxyl resin and the reinforcing fibers with the contact surface material; e) forming a configured exhaust manifold structure from the mixture of the silicon-carboxyl resin and the reinforcing fibers coated with the contact surface material by placing the mixture in at least a portion of monolithic ceramic material of casting and f) igniting the configured exhaust manifold structure at a temperature and for a time sufficient to convert the silicon-carboxyl to a ceramic.

The method according to claim 11, wherein the step of forming a silicon-carboxyl resin mixture and the reinforcing fibers coated with the contact surface material comprises: saturating a mat of the reinforcing fibers of woven fabric, coated with the contact surface material with the silicon-carboxyl resin.

The method according to claim 12 wherein the step of forming a configured exhaust manifold structure from the mixture of the silicon-carboxyl resin and the reinforcing fibers coated with the contact surface material additionally includes the step of: compressing the mat of the reinforcing fibers of the woven fabric coated with the contact surface material and saturated with the silicon-carboxyl resin in a mold under pressure before ignition.

The method according to claim 11 and, after the ignition step (f) further comprises the steps of: a) immersing the ignited manifold in a silicon-carboxyl resin bath to fill the pores formed by degassing with the silicon carboxyl resin; b) re-igniting the manifold at a temperature and for a time sufficient to convert the silicon-carboxyl to a ceramic; and c) repeating steps (a) and (b) until the remaining volume of the pores formed by degassing is below a quantity that maximizes the resistance of the manifold.

15. The method according to claim 11 and, after the ignition step (f), further comprises the steps of: a) placing the manifold in a mold; and b) pouring the molten metal into the mold around the manifold portions to add the additional structural metal compounds to the manifold.

16. The method according to claim 15 and, after the ignition step (e), further comprises the steps of: a) placing the manifold in a mold; and b) pouring the molten metal into the mold around the manifold portions to add the additional structural metal compounds to the manifold.

The method according to claim 1, wherein the step of coating the reinforcing fibers with a contact surface material comprises: coating the reinforcing fibers with a contact surface material, wherein the reinforcing fibers comprise ceramic fibers capable of withstanding high processing temperatures associated with the conversion of the pre-ceramic polymer resin to a ceramic matrix in an inert environment.

The method according to claim 4, wherein the step of forming a pre-ceramic polymer resin mixture and the reinforcing fibers coated with a contact surface material, comprising: mixing the coated reinforcing fibers with the contact surface material with a modified cement pre-ceramic polymer resin.

The method according to claim 1, wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material by placing the mixture on an internal portion of the cast monolithic ceramic material.

The method according to claim 1 wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the coated reinforcing fibers with the contact surface material placing the mixture on an external portion of the monolithic casting ceramic material.

21. The method according to claim 1, wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material by placing the mixture around the monolithic casting ceramic material.

22. The method according to claim 7, wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material by placing the mixture on an inner portion of the monolithic casting ceramic material.

The method according to claim 7, wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material by placing the mixture on an outer portion of the cast monolithic ceramic material.

The method according to claim 7, wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material by placing the mixture around the monolithic casting ceramic material.

The method according to claim 11 wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the coated reinforcing fibers with the contact surface material placing the mixture on an inner portion of the monolithic casting ceramic material.

26. The method according to claim 11 wherein the step of forming an exhaust manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the coated reinforcing fibers with the contact surface material by placing the mixture on an outer portion of the monolithic casting ceramic material.

The method according to claim 11 wherein the step of forming a contact manifold comprises: forming a configured exhaust manifold structure from the mixture of the pre-ceramic polymer resin and the coated reinforcing fibers with the contact surface material placing the mixture around the monolithic ceramic casting material.

28. An exhaust manifold of high temperature resistant fiber-reinforced ceramic matrix composite for an engine, comprising: a monolithic ceramic cast liner containing the pores saturated with a pre-ceramic polymer resin in a state of ceramics; reinforcing fibers coated with a contact surface material to prevent a pre-ceramic polymer resin from adhering strongly to the reinforcing fibers; a configured exhaust manifold structure formed from a mixture comprising a pre-ceramic polymer resin and the reinforcing fibers coated with a contact surface material; and wherein the mixture is disposed on at least a portion of monolithic casting ceramic material.

29. An exhaust manifold of high temperature resistant fiber-reinforced ceramic matrix composite for an engine, comprising: A monolithic ceramic cast liner containing saturated pores with a first pre-ceramic polymer resin in a state of ceramics; a configured exhaust manifold structure formed from a mixture comprising a second pre-ceramic polymer resin and reinforcing fibers coated with a contact surface material to prevent the second pre-ceramic polymer resin from adhering strongly to the reinforcing fibers; and wherein the mixture is disposed on at least a portion of the monolithic casting ceramic material.

The invention set forth in claim 29, wherein the reinforcing fibers are coated with at least one layer of the contact surface material of at least one carbon, silicon nitride, silicon carbide, silicon carboxyl or boron nitride.

31. The invention set forth in claim 29, wherein the reinforcing fibers are coated with at least one layer of the contact surface material of at least one of alumina, Altex, Nextel 312, Nextel 440, Nextel 510, Nextel. 550, silicon nitride, silicon carboxyl, carbon, or peat with the contact surface material.

The invention set forth in claim 29, wherein the blend further comprises a material selected from the group consisting of silicon-carboxyl resin pre-ceramic polymer resins, alumina silicate resin or monoaluminum phosphate resin, wherein the material is a modified cement resin, made from a system of an emulated structural polymer composite material.

33. The invention set forth in claim 29, wherein the blend comprises a mat of woven saturated fabric reinforcing fibers coated with the contact surface material and the pre-ceramic polymer resin.

The invention set forth in claim 29, wherein the reinforcing fibers comprise ceramic fibers capable of withstanding high processing temperatures associated with the conversion of the pre-ceramic polymer resin to a ceramic matrix in an inert environment.

35. The invention set forth in claim 29, wherein the blend further comprises a modified cement pre-ceramic polymer resin made from emulated methods of structural polymer composite systems.

36. The invention according to claim 29, wherein the mixture is located on an inner portion of the monolithic casting ceramic material.

37. The invention according to claim 29, wherein the mixture is located on an outer portion of the monolithic casting ceramic material.

38. The invention according to claim 29, wherein the mixture is located around the monolithic casting ceramic material.

39. An exhaust manifold of ceramic composite material reinforced with high temperature resistant fiber for an engine comprising: a monolithic ceramic cast liner having a first pre-ceramic polymer resin in a ceramic state located inside pores of the cast monolithic ceramic liner; reinforcing fibers coated with a contact surface material; and a configured structure of an exhaust manifold of a mixture comprising a second pre-ceramic polymer resin and the reinforcing fibers coated with the contact surface material; wherein the contact surface material prevents the second pre-ceramic polymer resin from adhering strongly to the reinforcing fibers, and wherein the mixture is disposed on at least a portion of monolithic cast ceramic material.

40. The invention according to claim 39, wherein the mixture further comprises a material selected from the group consisting of silicon-carboxyl resin pre-ceramic polymer resins, silicate-to-alumina resin, or phosphate-based resin. monoaluminium, wherein the material is a modified cement resin made from an emulsion structural polymer composite material system.

41. The invention according to claim 39, wherein the mixture is located on an internal portion of the monolithic casting ceramic material.

42. The invention according to claim 39, wherein the mixture is located on an outer portion of the monolithic casting ceramic material.

43. The invention according to claim 39, wherein the mixture is located around the monolithic casting ceramic material.