The film-boiling densification process for C/C composite fabrication: From local scale to overall optimization

The film-boiling densification process is an alternative of chemical vapor infiltration involving a strong thermal gradient. It allows to fabricate composite materials starting from a fibrous preform lying in a boiling hydrocarbon precursor, the cracking of which results in a solid deposit constituting the matrix of the carbon/carbon composite. A modelling approach is presented and validated with respect to experimental data. Then, the sensitivity of the process is studied with respect to various parameters. Optimization guidelines are proposed, in conjunction with a discussion on the densification front that characterizes the process. It is thus possible to evaluate the minimal amount of power required, while maintaining the quality of the produced material, i.e., its bulk density and homogeneity.