Chemical Vapour Infiltration (CVI) is one of the most effective and widely used process techniques for the fabrication of carbon fiber-reinforced carbon matrix (CFRC) composites. However, the CVI process is time-intensive, highly sensitive to process parameters, and demands precise control to achieve the desired microstructure of the pyrolytic carbon (PyC) matrix. In this study, a series of experiments were conducted by varying the CVI process parameter using a Taguchi orthogonal array design to systematically investigate the effects of key parameters on PyC deposition. The quality and microstructure of the deposited PyC were characterized using Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD), and Raman spectroscopy. The influence of temperature, pressure, methane gas flow rate, and nitrogen gas flow rate on the texture and graphitic structure of PyC was evaluated. Additionally, the impact of the graphitization process on the microstructure of PyC was evaluated. The results indicate that low temperature, low pressure, high methane flow rate, and low nitrogen flow rate favors the formation of high-texture, ordered crystalline PyC deposition. Each process parameter was found to significantly affect the resulting microstructure and crystalline quality of the CVI-deposited PyC. Based on this study, process guidelines are proposed for the densification of carbon fiber preform to realize C/C composite products for commercial and strategic applications.
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