Methods of producing a ceramic matrix composite

1. A method of forming a ceramic matrix composite component, the method comprising the steps of:

cutting at least one ply of a ceramic cloth into a preselected shape;

laying up the at least one ply in accordance with a design specification;

heating the at least one ply to a temperature sufficient to clean and desize the at least one ply;

placing the at least one cleaned and desized ply into a bag formed from non-ceramic material, the bag having at least one opening;

closing the at least one opening of the bag using sealing means to form a bagged ceramic perform; and

further comprising the step of stabilizing the bagged ceramic preform by stitching through the bagged ceramic preform.

2. A method of forming a ceramic matrix composite component, the method comprising the steps of:

cutting at least one ply of a ceramic cloth into a preselected shape;

laying up the at least one ply in accordance with a design specification;

heating the at least one ply to a temperature sufficient to clean and desize the at least one ply;

placing the at least one ply into a bag formed from non-ceramic material selected to permit infiltration of a ceramic slurry through the bag under vacuum, the bag having at least one opening;

closing the at least one opening of the bag using sealing means to form a bagged ceramic preform; and

of stabilizing the bagged ceramic preform by stitching through the bagged ceramic preform.

3. A method of forming a ceramic matrix composite component, the method comprising the steps of:

cutting at least one ply of a ceramic cloth into a preselected shape;

laying up the at least one ply in accordance with a design specification;

heating the at least one ply to a temperature sufficient to clean and desize the at least one ply;

placing the at least one cleaned and desized ply into a bag formed from non-ceramic material, the bag having at least one opening; and

closing the at least one opening of the bag using sealing means to form a bagged ceramic perform;

further comprising the step of infiltrating the bagged ceramic perform with a ceramic-containing slurry, wherein the step of infiltrating the bagged ceramic perform comprises the steps of:

placing the bagged ceramic preform into a slurry infiltration unit;

placing the bagged ceramic preform on a shape-forming mold;

placing the bagged ceramic preform and shape forming mold into a vacuum-type slurry infiltration unit; and

infiltrating the bagged ceramic preform, wherein the step of infiltrating the bagged ceramic preform comprises the steps of:

providing an open weave material;

soaking the open weave material with a ceramic-containing slurry;

placing the soaked open weave material in substantial contact with the non-ceramic bag material of the bagged ceramic preform to form a sandwich;

sealing the sandwich in a vacuum-type slurry infiltration unit; and

operating the slurry infiltration unit to draw the slurry out of the open weave material and into the ceramic cloth of the bagged ceramic preform to form an infiltrated bagged ceramic preform.

4. The method of claim 3 , farther comprising the step of drying the infiltrated bagged preform to form an infiltrated dried bagged preform.

5. The method of claim 4 , wherein the step of drying the infiltrated bagged preform is performed in ambient conditions.

6. The method of claim 4 , flirt her comprising the step of: laminating the infiltrated dried bagged ceramic preform to consolidate the infiltrated dried bagged ceramic preform.

7. The method of claim 6 , farther comprising the step of, after consolidating: sintering the dried infiltrated bagged ceramic preform at a temperature sufficient to convert the ceramic-containing slurry in the preform to a ceramic and to decompose the non-ceramic bag material to form a CMC component.

8. The method of claim 7 , farther comprising the step of, after sintering:

removing the decomposed non-ceramic bag material.

9. The method of claim 8 , wherein the step of removing the decomposed non-ceramic bag material includes sanding the CMC component.

10. The method of claim 8 , wherein the step of removing the decomposed non-ceramic bag material includes sandblasting the CMC component.

11. A method of forming a ceramic matrix composite component, the method comprising the steps of:

cutting at least one ply of a ceramic cloth into a preselected shape;

laying up the at least one ply in accordance with a design specification;

heating the at least one ply to a temperature sufficient to clean and desize the at least one ply;

placing the cleaned and desized ply into a bag formed from non-ceramic material, the bag having at least one opening;

closing the at least one opening of the bag using sealing means to form a bagged ceramic preform;

stabilizing the bagged ceramic prefrom;

mating the bagged ceramic preform to a fabrication tool;

providing an open weave material;

soaking the open weave material with a ceramic-containing slurry;

placing the soaked open weave material in substantial contact with the non-ceramic bag material of the bagged ceramic preform to form a sandwich;

sealing the sandwich in a vacuum-type slurry infiltration unit;

operating the slurry infiltration unit to draw the slurry out of the open weave material and into the ceramic cloth of the bagged ceramic preform to form an infiltrated bagged ceramic preform; and

drying the infiltrated bagged preform.

12. The method of claim 11 , further comprising the steps of:

laminating the infiltrated bagged ceramic preform to consolidate the infiltrated bagged ceramic preform; and

sintering the infiltrated bagged ceramic preform at a temperature sufficient to convert the ceramic-containing slurry in the preform to a ceramic and to decompose the non-ceramic bag material to form a CMC component.

13. The method of claim 11 , wherein the step of stabilizing the preform comprises stitching through the bagged ceramic preform.

14. A method of forming a ceramic matrix composite component, the method comprising the steps of:

cutting at least one ply of a ceramic cloth into a preselected shape;

laying up the at least one ply in accordance with a design specification

heating the at least one ply to a temperature sufficient to clean and desize the at least one ply;

placing the at least one ply into a bag formed from non-ceramic material selected to permit infiltration of a ceramic slurry through the bag under vacuum, the bag having at least one opening;

closing the at least one opening of the bag using sealing means to form a bagged ceramic preform; and

infiltrating the bagged ceramic preform with a ceramic-containing slurry,

wherein the step of infiltrating the bagged ceramic preform farther comprises the steps of:

placing the bagged ceramic preform on a shape-forming mold;

placing the bagged ceramic preform and shape forming mold into a slurry infiltration unit; and

infiltrating the bagged ceramic preform,

wherein the step of placing the bagged ceramic preform into a slurry infiltration unit includes placing the preform into a vacuum-type slurry infiltration unit, and wherein the step of infiltrating the bagged ceramic preform comprises the steps of:

providing an open weave material;

soaking the open weave material with a ceramic-containing slurry;

placing the soaked open weave material in substantial contact with the non-ceramic bag material of the bagged ceramic preform to form a sandwich;

sealing the sandwich in a vacuum-type slurry infiltration unit; and operating the slurry infiltration unit to draw the slurry out of the open weave material and into the ceramic cloth of the bagged ceramic preform to form an infiltrated bagged ceramic perform.