Fiber reinforced ceramic matrix composites: from the controlled fabrication to precision machining

Abstract Fiber reinforced ceramic matrix composites (FRCMCs) are the preferred materials for safety critical components in the fields of aerospace, nuclear engineering, and transportation, with broad market and application prospects. However, due to the characteristics of multiphase, heterogeneity, and anisotropy, key issues such as poor adhesion, high porosity, and crack propagation urgently need to be addressed in the fabrication and machining of FRCMCs. With the increasing demand for FRCMCs parts, high-quality and reliable design and fabrication, performance evaluation, and precision manufacturing have become a series of hot issues. There is a lack of systematic review in capturing the current research status and development direction of FRCMCs fabrication and machining. This research aims to comprehensively review and critically evaluate the existing understanding of the fabrication and machining of FRCMCs. This study can provide scientists with a deeper understanding of the shape control mechanism of FRCMCs fabrication and machining, the theoretical basis of material synchronous removal, machining performance, and development direction. Firstly, the basic characteristics and application background of FRCMCs are introduced. Secondly, by comparing and analyzing the typical fabrication process of FRCMCs, the advantages, disadvantages, and performance evaluation of different processes are comprehensively evaluated. Thirdly, the material removal mechanisms and machining performance evaluation standards of traditional mechanical machining technologies (drilling, milling, grinding) and non-traditional mechanical machining technologies (ultrasonic, laser, water jet, discharge, wire saw, and multi-field hybrid machining) are discussed and analyzed. Finally, the challenges, development trends, and prospects faced by FRCMCs in the fields of fabrication, machining, and application are analyzed. This study not only elucidates the basic processes and key difficulties in the fabrication of FRCMCs, but also provides valuable insights for low-damage machining.