METHOD OF PRODUCING A CERAMIC ARTICLE, INTERMEDIATE ARTICLE AND COMPOSITION THEREFOR
A method of producing a ceramic material includes heating solid silicon monoxide to provide gaseous silicon monoxide, and exposing a structure having a free-carbon-containing material to the gaseous silicon monoxide to convert free carbon of the free-carbon-containing material to silicon carbide. Also disclosed is an intermediate article that includes a solid structure having free carbon and a solid, in-situ source of silicon monoxide gas. Also disclosed is a composition that includes a polymeric carrier phase and particulate of solid silicon monoxide dispersed in the polymeric carrier phase.
1 . A method of producing a ceramic article, the method comprising:
heating solid silicon monoxide to provide gaseous silicon monoxide; and
exposing a structure having a free-carbon-containing material to the gaseous silicon monoxide to convert free carbon of the free-carbon-containing material to silicon carbide.
2 . The method as recited in claim 1 , further comprising providing the solid silicon monoxide as a particulate dispersed in a coating on at least a portion of the structure.
3 . The method as recited in claim 2 , wherein the coating includes a polymeric carrier phase and the particulate of the solid silicon monoxide is dispersed in the polymeric carrier phase.
4 . The method as recited in claim 3 , wherein the exposing includes heating the coated structure to convert the particulate of the solid silicon monoxide in the polymeric carrier phase to the gaseous silicon monoxide.
5 . The method as recited in claim 3 , wherein the particulate of the solid silicon monoxide is provided in an amount that is stoichiometrically equal to or greater than the amount of free carbon.
6 . The method as recited in claim 3 , wherein the polymeric carrier phase is a preceramic polymer, and further including converting the preceramic polymer phase to a ceramic material.
7 . The method as recited in claim 1 , wherein the free carbon is residual free carbon from a prior thermal process used to form the structure.
8 . The method as recited in claim 1 , wherein the free carbon is in a coating on the structure.
9 . The method as recited in claim 1 , wherein the structure is an elongated, uniform diameter fiber.
10 . The method as recited in claim 1 , wherein the structure is a porous body.
11 . An intermediate article comprising:
a solid structure having free carbon and a solid, in-situ source of silicon monoxide gas.
12 . The intermediate article as recited in claim 11 , wherein the solid structure is selected from the group consisting of an elongated, uniform diameter fiber and a porous body.
13 . The intermediate article as recited in claim 11 , wherein the solid, in-situ source of silicon monoxide gas is a particulate that is dispersed in a polymeric carrier phase.
14 . The intermediate article as recited in claim 13 , wherein the polymeric carrier phase is a preceramic polymer.
15 . The intermediate article as recited in claim 11 , wherein the free carbon is in a coating of the solid structure.
16 . A composition comprising:
a polymeric carrier phase; and
particulate of solid silicon monoxide dispersed in the polymeric carrier phase.
17 . The composition as recited in claim 16 , wherein the polymeric carrier phase is a preceramic polymer.