Fabrication of continuous fiber reinforced ceramic matrix mini-composites via direct ink writing

Abstract

Ceramic materials are valued for their exceptional heat and corrosion resistance, yet their inherent brittleness limits their use in applications requiring high strength-to-weight ratios, fatigue resistance, and durability under harsh conditions, such as those in the aerospace and automotive industries. The development of ceramic matrix composites (CMCs), incorporating continuous reinforcements, has enhanced the mechanical performance of ceramics, offering superior toughness compared to randomly oriented composites. Traditional fabrication methods for composites, such as polymer infiltration and pyrolysis (PIP) and chemical vapor infiltration (CVI), are effective but constrained by shaping complexities. Direct ink writing (DIW) has emerged as a fabrication approach for CMCs fabrication, enabling custom geometries and tailored reinforcement architectures. Extrusion-based processes naturally align fibers, optimizing their orientation and enhancing composite properties. This study focuses on the fabrication of silicon oxycarbide matrix reinforced with continuous carbon fibers using two DIW approaches. Comparative analysis highlighted the benefits and limitations of each method, with post-processing via PIP addressing crack formation and improving densification. Mechanical properties were evaluated at different fabrication stages, revealing key relationships between processing techniques and final composite performance.