System and method for forming an ultra-high temperature composite structure

1. A system for forming an ultra-high temperature (UHT) composite structure, the system comprising

an electrospinning apparatus comprising a spinneret disposed at a first end of a flowpath and biased at a first DC voltage;

a collector disposed at a second end of the flowpath and spaced from the spinneret along the flowpath, the collector biased at a second DC voltage different than the first DC voltage;

an electrospraying apparatus comprising a nozzle biased at a third DC voltage different than the second DC voltage;

a rapid thermal processing assembly; and

a controller comprising a processor in signal communication with a non-transitory memory storing instructions which, when executed by the processor, cause the processor to:

control the electrospinning apparatus to dispense a first polymeric precursor, with the spinneret, onto the collector forming a first plurality of nanofibers on the collector;

control the electrospraying apparatus to apply a fluid, with the nozzle, onto the first plurality of nanofibers disposed on the collector, the fluid comprising a second polymeric precursor, the first plurality of nanofibers and the fluid defining a two-dimensional layer;

control the rapid thermal processing assembly to pyrolyze the two-dimensional layer; and

control the electrospinning apparatus to dispense the first polymeric precursor, with the spinneret, onto the two-dimensional layer, subsequent to pyrolyzing the two-dimensional layer, forming a second plurality of nanofibers on the two-dimensional layer.

2. The system of claim 1 , wherein the nozzle is configured to move relative to the collector.

3. The system of claim 1 , wherein the second polymeric precursor is different than the first polymeric precursor.

4. The system of claim 3 , wherein the first polymeric precursor has a greater viscosity than the second polymeric precursor.

5. The system of claim 1 , wherein the rapid thermal processing assembly comprises at least one of a laser, an electron beam, or a flash pyrolysis assembly.

6. The system of claim 1 , wherein the spinneret and the collector are configured to move relative to one another.

7. The system of claim 1 , wherein pyrolyzing the two-dimensional layer includes carbothermally or borothermally reduce the two-dimensional layer.

8. The system of claim 1 , wherein the instructions, when executed by the processor, further cause the processor to, subsequent to controlling the rapid thermal processing assembly to pyrolyze the two-dimensional layer and prior to controlling the electrospinning apparatus to dispense the first polymeric precursor, with the spinneret, onto the two-dimensional layer:

control the electrospraying apparatus to apply the fluid, with the nozzle, onto the two-dimensional layer; and

control the rapid thermal processing assembly to pyrolyze the two-dimensional layer.

9. A system for forming an ultra-high temperature (UHT) composite structure, the system comprising

an electrospinning apparatus comprising a spinneret biased at a first DC voltage;

a collector biased at a second DC voltage different than the first DC voltage;

an electrospraying apparatus comprising a nozzle biased at a third DC voltage different than the second DC voltage;

a rapid thermal processing assembly; and

a controller comprising a processor in signal communication with a non-transitory memory storing instructions which, when executed by the processor, cause the processor to sequentially form a plurality of composite material layers on the collector by, for each sequentially-formed composite material layer:

controlling the electrospinning apparatus to dispense a first polymeric precursor, with the spinneret, onto the collector forming a plurality of nanofibers;

controlling the electrospraying apparatus to apply a fluid, with the nozzle, onto the plurality of nanofibers disposed on the collector, the fluid comprising a second polymeric precursor; and

controlling the rapid thermal processing assembly to pyrolyze the plurality of nanofibers and the fluid forming a respective one of the plurality of composite material layers.

10. The system of claim 9 , wherein the first polymeric precursor is different than the second polymeric precursor.

11. The system of claim 10 , wherein the first polymeric precursor has a greater viscosity than the second polymeric precursor.

12. The system of claim 9 , wherein the rapid thermal processing assembly includes at least one of a laser, an electron beam, or a flash pyrolysis assembly.

13. The system of claim 9 , wherein pyrolyzing the plurality of nanofibers and the fluid includes carbothermally or borothermally reducing the plurality of nanofibers and the fluid.

14. The system of claim 9 , wherein the instructions, when executed by the processor, further cause the processor to sequentially form the plurality of composite material layers on the collector by, for each sequentially-formed composite material layer:

control the electrospraying apparatus to apply the fluid, with the nozzle, onto the respective one of the plurality of composite material layers subsequent to pyrolyzing the plurality of nanofibers and the fluid; and

control the rapid thermal processing assembly to pyrolyze the respective one of the plurality of composite material layers subsequent to controlling the electrospraying apparatus to apply the fluid, with the nozzle, onto the respective one of the plurality of composite material layers.

15. A system for forming an ultra-high temperature (UHT) composite structure, the system comprising

an electrospinning apparatus comprising a spinneret and a plurality of magnets, the spinneret biased at a first DC voltage;

a collector biased at a second DC voltage different than the first DC voltage;

an electrospraying apparatus comprising a nozzle biased at a third DC voltage different than the second DC voltage;

a rapid thermal processing assembly; and

a controller comprising a processor in signal communication with a non-transitory memory storing instructions which, when executed by the processor, cause the processor to:

deposit a first plurality of nanofibers on the collector by controlling the electrospinning apparatus to form the first plurality of nanofibers by dispensing a first polymeric precursor, with the spinneret, and adjusting a magnetic field of the plurality of magnets to align the first plurality of nanofibers on the collector;

control the electrospraying apparatus to apply a fluid, with the nozzle, onto the first plurality of nanofibers disposed on the collector, the fluid comprising a second polymeric precursor;

control the rapid thermal processing assembly to pyrolyze the first plurality of nanofibers and the fluid on the collector; and

deposit a second plurality of nanofibers on the collector by controlling the electrospinning apparatus to form the second plurality of nanofibers by dispensing the first polymeric precursor, with the spinneret, subsequent to pyrolyzing the first plurality of nanofibers and the fluid.

16. The system of claim 15 , wherein the nozzle is configured to move relative to the collector.

17. The system of claim 15 , wherein the second polymeric precursor is different than the first polymeric precursor.

18. The system of claim 17 , wherein the first polymeric precursor has a greater viscosity than the second polymeric precursor.

19. The system of claim 15 , wherein the rapid thermal processing assembly comprises at least one of a laser, an electron beam, or a flash pyrolysis assembly.

20. The system of claim 15 , wherein the spinneret and the collector are configured to move relative to one another.