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Densification
and coating deposition

The densification of carbon fiber composites is a crucial process for achieving high-performance materials, particularly used in the aerospace, automotive, and sporting sectors. This stage aims to reduce porosity and improve the mechanical strength of the final component.

The densification of carbon fiber composites through processes such as CVI (Chemical Vapor Infiltration) and LSI (Liquid Silicon Infiltration) is essential for the production of ceramic matrix materials, such as C/C or C/SiC. In CVI, a gaseous precursor penetrates the porous fiber preform and, through high-temperature chemical reactions, deposits a solid matrix inside.

This process gradually reduces porosity, enhancing cohesion and mechanical properties. On the other hand, LSI involves the infiltration of liquid silicon into a carbon preform, forming compounds like SiC. Both methods ensure high thermal and structural performance, making them ideal for aerospace and energy applications.

FCT

Liquid Silicon Infiltration and coating deposition

CVI

Chemical Vapour Infiltration

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Liquid Silicon Infiltration
and coating deposition


Petroceramics has been working on the liquid silicon infiltration process for over 15 years, playing a key role in the development of carboceramic materials for automotive applications. Petroceramics holds the patent “Method for the infiltration of a porous material with a second material and related apparatus” (WO2012123907, EP2686285, CN103547549, US2014072710), which claims an innovative LSI process.

With our approach the capillary forces are so strong that the pores are filled simultaneously, regardless of their size. This results in a rapid infiltration that can be achieved in just a few minutes, rather than in hours as would occur in the conventional process. The final porosity of the infiltrated material is drastically reduced. The reaction interfaces between the carbon fibers and the molten silicon are minimized, and the carbon fibers are better preserved.

Petroceramics has also developed and patented a method for the deposition of SiC coatings on the surface of C/C and C/SiC composites (Patent WO 2021/053528). This process does not affect the properties of the materials, as it is carried out under vacuum at temperatures lower than those used in the silicon infiltration process.


Vacuum oven

TAV 329
Max vacuum10-3mbar
Max temperature2000°C
Chamber volume50L (L=420mm, H=400mm)


Vacuum oven

FCT
Max vacuum10-2 mbar
Chamber atmosphereNitrogen
Max temperature1800°C
Chamber volume1325L (D=1500 mm, H=750 mm)

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Chemical Vapour Infiltration


Chemical Vapor Infiltration (CVI) is widely used to develop ceramic matrix composites. This method is employed to deposit solid materials such as carbon, silicon carbide, boron nitride, and other refractory materials into a porous fiber structure through the decomposition of vapors.

Thanks to our extensive expertise, we are able to infiltrate various matrices with large and complex-shaped products. We have developed specific processes to produce materials with minimal fiber damage and low residual stresses.

CVI oven

CVI
Max vacuum45 mbar
Chamber atmosphereAzoto / Metano / Propano
Max temperature1200°C
Chamber volume70L