Advanced polymer impregnation and pyrolysis (PIP) of SiOC-based ceramic matrix composites (CMCs)

W. Jordan Wright; Marco C. Martinez; Kinga A. Unocic; Stephanie M. Curlin; Michael J. Lance; Steve E. Bullock; David J. Mitchell; Corson L. Cramer

doi:10.1016/j.jeurceramsoc.2025.117668

Advanced polymer impregnation and pyrolysis (PIP) of SiOC-based ceramic matrix composites (CMCs)

W. Jordan Wright
, Marco C. Martinez
, Kinga A. Unocic
, Stephanie M. Curlin
, Michael J. Lance
, Steve E. Bullock
, David J. Mitchell
, Corson L. Cramer

Research output: Contribution to journal › Article › peer-review

7 Scopus citations

Abstract

Silicon carbide (SiC) ceramic matrix composites (CMCs) are valued for their high-temperature properties, making them ideal for harsh environments. However, conventional polymer impregnation and pyrolysis (C-PIP) often result in porous composites and require numerous cycles for densification. This study introduces the advanced PIP (A-PIP) method using a crosslinked polycarbosiloxane (PCS) precursor to enhance densification efficiency. Five SiC CMCs were fabricated using C-PIP and A-PIP, with variations in fiber reinforcement and fiber coatings. A-PIP achieved up to 19 % higher density and 78 % lower porosity in 79–86 % less processing time compared to C-PIP. Moreover, SiC-SiOC composites with boron nitride-coated fibers showed significant improvements in tensile strength (11 MPa to 134 MPa) and strain at maximum strength (0.01–0.11 %), underscoring the role of weak fiber-matrix interfaces. These results demonstrate A-PIP's potential to produce dense, low-porosity SiC CMCs more efficiently, significantly reducing manufacturing time and costs.

Original language	English
Article number	117668
Journal	Journal of the European Ceramic Society
Volume	45
Issue number	16
DOIs	https://doi.org/10.1016/j.jeurceramsoc.2025.117668
State	Published - Dec 2025

Funding

This manuscript has been authored by UT-Battelle LLC under Contract No. DE-AC05–00OR22725 with the U.S. Department of Energy. The project was funded by the Advanced Materials & Manufacturing Technologies Office (AMMTO) under contract DE-FOA-0002252: Reducing Cost of Production of Ceramic Matrix Composites Used in High Temperature Applications with Robocasting Enterprises, LLC. The authors would like to thank Tracie Lowe for SEM imaging help, Daniel Rasmussen for CMC fabrication assistance, Ashli Clark for CMC processing assistance, Luke Smith for CMC processing assistance, and Daniel Newberry for sample prep and imaging. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05–00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( https://www.energy.gov/doe-public-access-plan ).

Keywords

Carbon Fiber
Ceramic Matrix Composites
Polymer Impregnation and Pyrolysis (PIP)
Silicone Carbide Fiber

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10.1016/j.jeurceramsoc.2025.117668

Cite this

@article{0493ddfc74cf45d7b5149b79d3301d53,

title = "Advanced polymer impregnation and pyrolysis (PIP) of SiOC-based ceramic matrix composites (CMCs)",

abstract = "Silicon carbide (SiC) ceramic matrix composites (CMCs) are valued for their high-temperature properties, making them ideal for harsh environments. However, conventional polymer impregnation and pyrolysis (C-PIP) often result in porous composites and require numerous cycles for densification. This study introduces the advanced PIP (A-PIP) method using a crosslinked polycarbosiloxane (PCS) precursor to enhance densification efficiency. Five SiC CMCs were fabricated using C-PIP and A-PIP, with variations in fiber reinforcement and fiber coatings. A-PIP achieved up to 19 \% higher density and 78 \% lower porosity in 79–86 \% less processing time compared to C-PIP. Moreover, SiC-SiOC composites with boron nitride-coated fibers showed significant improvements in tensile strength (11 MPa to 134 MPa) and strain at maximum strength (0.01–0.11 \%), underscoring the role of weak fiber-matrix interfaces. These results demonstrate A-PIP's potential to produce dense, low-porosity SiC CMCs more efficiently, significantly reducing manufacturing time and costs.",

keywords = "Carbon Fiber, Ceramic Matrix Composites, Polymer Impregnation and Pyrolysis (PIP), Silicone Carbide Fiber",

author = "Wright, \{W. Jordan\} and Martinez, \{Marco C.\} and Unocic, \{Kinga A.\} and Curlin, \{Stephanie M.\} and Lance, \{Michael J.\} and Bullock, \{Steve E.\} and Mitchell, \{David J.\} and Cramer, \{Corson L.\}",

note = "Publisher Copyright: {\textcopyright} 2025 Elsevier Ltd",

year = "2025",

month = dec,

doi = "10.1016/j.jeurceramsoc.2025.117668",

language = "English",

volume = "45",

journal = "Journal of the European Ceramic Society",

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T1 - Advanced polymer impregnation and pyrolysis (PIP) of SiOC-based ceramic matrix composites (CMCs)

AU - Wright, W. Jordan

AU - Martinez, Marco C.

AU - Unocic, Kinga A.

AU - Curlin, Stephanie M.

AU - Lance, Michael J.

AU - Bullock, Steve E.

AU - Mitchell, David J.

AU - Cramer, Corson L.

PY - 2025/12

Y1 - 2025/12

N2 - Silicon carbide (SiC) ceramic matrix composites (CMCs) are valued for their high-temperature properties, making them ideal for harsh environments. However, conventional polymer impregnation and pyrolysis (C-PIP) often result in porous composites and require numerous cycles for densification. This study introduces the advanced PIP (A-PIP) method using a crosslinked polycarbosiloxane (PCS) precursor to enhance densification efficiency. Five SiC CMCs were fabricated using C-PIP and A-PIP, with variations in fiber reinforcement and fiber coatings. A-PIP achieved up to 19 % higher density and 78 % lower porosity in 79–86 % less processing time compared to C-PIP. Moreover, SiC-SiOC composites with boron nitride-coated fibers showed significant improvements in tensile strength (11 MPa to 134 MPa) and strain at maximum strength (0.01–0.11 %), underscoring the role of weak fiber-matrix interfaces. These results demonstrate A-PIP's potential to produce dense, low-porosity SiC CMCs more efficiently, significantly reducing manufacturing time and costs.

AB - Silicon carbide (SiC) ceramic matrix composites (CMCs) are valued for their high-temperature properties, making them ideal for harsh environments. However, conventional polymer impregnation and pyrolysis (C-PIP) often result in porous composites and require numerous cycles for densification. This study introduces the advanced PIP (A-PIP) method using a crosslinked polycarbosiloxane (PCS) precursor to enhance densification efficiency. Five SiC CMCs were fabricated using C-PIP and A-PIP, with variations in fiber reinforcement and fiber coatings. A-PIP achieved up to 19 % higher density and 78 % lower porosity in 79–86 % less processing time compared to C-PIP. Moreover, SiC-SiOC composites with boron nitride-coated fibers showed significant improvements in tensile strength (11 MPa to 134 MPa) and strain at maximum strength (0.01–0.11 %), underscoring the role of weak fiber-matrix interfaces. These results demonstrate A-PIP's potential to produce dense, low-porosity SiC CMCs more efficiently, significantly reducing manufacturing time and costs.

KW - Carbon Fiber

KW - Ceramic Matrix Composites

KW - Polymer Impregnation and Pyrolysis (PIP)

KW - Silicone Carbide Fiber

UR - https://www.scopus.com/pages/publications/105010298895

U2 - 10.1016/j.jeurceramsoc.2025.117668

DO - 10.1016/j.jeurceramsoc.2025.117668

M3 - Article

AN - SCOPUS:105010298895

SN - 0955-2219

VL - 45

JO - Journal of the European Ceramic Society

JF - Journal of the European Ceramic Society

IS - 16

M1 - 117668

ER -

Advanced polymer impregnation and pyrolysis (PIP) of SiOC-based ceramic matrix composites (CMCs)

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