Microstructure and mechanical properties of continuous carbon fiber-reinforced SiC ceramic composite fabricated by direct ink writing

The direct ink writing (DIW) technique is considered efficient for manufacturing complex-shaped Cf/SiC composites. However, the SiC slurry with high load has poor flow ability and covering-fibers properties, resulting in numerous gaps between the ceramic matrix and fibers. This study utilized DIW to manufacture Cf/SiC composites and improved the slurry's printing ability by adjusting the binder content. Moreover, the printing parameters, such as the angle between the fiber nozzle and slurry nozzle and the slurry nozzle size, were optimized to enhance the accuracy of the body structure and the filling effect of the slurry on the fiber gaps. The results showed that a binder content of 0.4 wt% produced excellent thixotropic, viscoelastic, and shear thinning behavior in the slurry. By using a fiber nozzle angle of 60 degrees and a nozzle diameter of 1.55 mm, the slurry effectively filled the gaps between the fiber bundle and matrix, reducing the number and size of pores in the SiC matrix. These improvements greatly enhance the density, strength, and fracture toughness of the Cf/SiC composites. Therefore, this research demonstrated that optimizing the printing parameters not only improved the structural accuracy of the printed bodies but also greatly enhanced the properties of the ceramic matrix composites.