Volume 103, Issue 12 p. 6712-6723
ORIGINAL ARTICLE

Additive manufacturing of polymer-derived ceramic matrix composites

Mark R. O'Masta

Corresponding Author

Mark R. O'Masta

HRL Laboratories, LLC, Malibu, CA, USA

Correspondence

Mark R. O'Masta and Tobias A. Schaedler, HRL Laboratories, LLC, 3011 Malibu Canyon Road, Malibu, CA 90265, USA.

Email: [email protected] (M. R. O.) and [email protected] (T. A. S.)

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Ekaterina Stonkevitch

Ekaterina Stonkevitch

HRL Laboratories, LLC, Malibu, CA, USA

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Kayleigh A. Porter

Kayleigh A. Porter

HRL Laboratories, LLC, Malibu, CA, USA

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Phuong P. Bui

Phuong P. Bui

HRL Laboratories, LLC, Malibu, CA, USA

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Zak C. Eckel

Zak C. Eckel

HRL Laboratories, LLC, Malibu, CA, USA

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Tobias A. Schaedler

Corresponding Author

Tobias A. Schaedler

HRL Laboratories, LLC, Malibu, CA, USA

Correspondence

Mark R. O'Masta and Tobias A. Schaedler, HRL Laboratories, LLC, 3011 Malibu Canyon Road, Malibu, CA 90265, USA.

Email: [email protected] (M. R. O.) and [email protected] (T. A. S.)

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First published: 28 May 2020
Citations: 29

Abstract

This study presents a fabrication method and identifies processing bounds for additively manufacturing (AM) ceramic matrix composites (CMCs), comprising a silicon oxycarbide (SiOC) ceramic matrix. A digital light projection printer was used to photopolymerize a siloxane-based preceramic resin containing inert ceramic reinforcement. A subsequent pyrolysis converted the preceramic polymer to SiOC. Particle reinforcements of 0 to 40% by volume in the green state were uniformly dispersed in the printed samples to study their effects on pyrolysis mass loss and shrinkage, and CMC notch sensitivity and strength. Both particle and whisker reinforcements toughened the glassy SiOC matrix (1 MPa m1/2), reaching values >3 MPa m1/2. Bending strengths of >300 MPa (>150 MPa (g cm−3)−1) and a Weibull modulus of 10 were measured on AM samples without surface finish. We identified two pore formation mechanisms that placed processing bounds on sample size and reinforcement volume fraction. Methods for increasing these bounds are discussed. With properties commensurate to traditionally processed technical ceramics, the presented process allows for free-form fabrication of high-performance AM CMC components.