Fast Densification of Carbon-Carbon Composites

Carbon-Carbon composites are used in a variety of applications such as thermal protection systems, satellite structures, turbine engine components, and aircraft brakes. The cost of these carbon-carbon components are generally high due to the long process times required to achieve fully densified parts. Current densification practices using carbon vapor deposition, low pressure impregnation and carbonization, or high pressure impregnation and carbonization generally require from 12 to 18 weeks to achieve full density. A novel approach is proposed to significantly reduce the number of process cycles needed to achieve full densification. The new process uses a modified high char yielding pitch precursor together with a newly demonstrated sensor controlled carbonization process to potentially reduce the densification time from 12 weeks to 4 weeks. In addition, the proposed process can be used with the simpler low pressure impregnation and carbonization precedure for added cost savings.