Ceramic matrix composite materials with rare earth phosphate fibers and methods for preparing the same

1. A ceramic matrix composite (CMC) material comprising rare earth phosphate ceramic fibers consisting of YPO 4 or YbPO 4 embedded in a ceramic matrix, wherein the ceramic matrix comprises a rare earth phosphate material.

2. The CMC material of claim 1 , wherein the rare earth phosphate ceramic fibers are present in an amount, based on an overall volume of ceramic fibers in the CMC material, of about 5% to about 95% by volume.

3. The CMC material of claim 1 , further comprising ceramic fibers consisting of aluminosilicate or alumina embedded in the ceramic matrix.

4. The CMC material of claim 1 , wherein the ceramic matrix further comprises alumina, aluminosilicate, aluminum phosphate, or rare earth silicates.

5. The CMC material of claim 1 , wherein the rare earth phosphate material is present in an amount, based on an overall volume of ceramic matrix in the CMC material, of about 5% to about 95% by volume.

6. A method for manufacturing a ceramic matrix composite (CMC) material comprising the steps of:

weaving ceramic fibers into a mat structure, wherein the ceramic fibers comprise rare earth phosphate ceramic fibers;

infiltrating the ceramic fiber mat structure with a ceramic matrix precursor slurry to form a slurry-infiltrated ceramic fiber mat structure; and

heating the slurry-infiltrated ceramic fiber mat structure to form the CMC material.

7. The method of claim 6 , further comprising the step of manufacturing the ceramic fibers prior to the step of weaving the ceramic fibers.

8. The method of claim 7 , wherein the step of manufacturing the ceramic fibers is performed using a sol-gel process.

9. The method of claim 6 , wherein the step of weaving ceramic fibers comprises weaving ceramic fibers that consist of a material selected from the group consisting of: LaPO 4 , YPO 4 , CePO 4 , ScPO 4 , PrPO 4 , NdPO 4 , SmPO 4 , EuPO 4 , HoPO 4 , TmPO 4 , ErPO 4 , YbPO 4 , LuPO 4 , DyPO 4 , TbPO 4 , GdPO 4 and combinations of two or more thereof.

10. The method of claim 6 , further comprising the step of manufacturing the ceramic matrix precursor slurry prior to the step of infiltrating the ceramic fiber mat structure.

11. The method of claim 10 , wherein the step of manufacturing the ceramic matrix precursor slurry comprises the sub-steps of:

heat treating an amorphous powder to remove volatile compounds therefrom and to transform the amorphous powder into a crystalline structure powder;

milling the crystalline structure powder to reduce a size of crystals in the crystalline structure powder; and

mixing the crystalline structure powder with a binder or dispersant to form the ceramic matrix precursor slurry.

12. The method of claim 11 , wherein the sub-step of heat treating the amorphous powder comprises heat treating a rare earth phosphate ceramic amorphous powder.

13. The method of claim 6 , wherein the step of heating the slurry-infiltrated ceramic fiber mat structure comprises heating at or above about 1000° C.

14. A gas turbine engine comprising a gas turbine engine component, wherein the gas turbine engine component is formed at least in part of a ceramic matrix composite (CMC) material, and wherein the CMC material comprises rare earth phosphate ceramic fibers consisting of YPO 4 or YbPO 4 embedded in a ceramic matrix.

15. The gas turbine engine of claim 14 , wherein the gas turbine engine component is selected from the group consisting of: a blade, a vane, a nozzle, a duct, and a combustion liner.

16. The gas turbine engine of claim 14 , wherein the gas turbine engine component further comprises an insulating material layer overlaying the CMC material, and wherein the insulating material layer comprises a rare earth phosphate ceramic material.

17. The gas turbine engine of claim 16 , wherein the gas turbine engine component further comprises protective outer coating overlaying the insulating material layer.