Low-cost and reliable production of oxide ceramic matrix composites

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For advanced ceramics composites, affordable manufacturing is still the most essential shortcoming with respect to successful commercial use. This holds particularly for components made out of composites with complex hierarchical structure and high demands of mechanical performance and reliability at the same time., e.g. fibre-reinforced ceramic composites (FRCMCs) which have been developed to overcome the intrinsic brittleness and lack of reliability of monolithic ceramics. Their major advantages include higher temperature capability, lighter weight, better corrosion resistance and adequate damage tolerance. There is a wide spectrum of FRCMCs depending on the chemical composition of the matrix and reinforcement although at present only Cf-C/SiC composites produced by the silicon infiltration route have obtained commercial production level. However, fibre reinforced composites based on oxides (Oxide-Oxide FRCMC) would offer essential advantages with respect to long time stability in oxidizing atmospheres. Although in the past decades there has been a considerable interest in Oxide-Oxide FRCMC, there is at present almost no production concept which meet the requirements in view of cost and performance. Here, this proposal starts and focus on a new concept based on the integration of two reactive production routes for alumina employed at TUHH (reaction bonding sintering) and UFSC (biotemplated alumina by Al vapour infiltration) which will give advanced performance and low production costs at the same time . For this route, an advanced shaping based on CAD/CAM concept (rapid prototyping by LOM) can be integrated additionally favouring easy small scale manufacturing which is in general very typical for these materials.