SBIR-STTR Award

NASA has identified a need to reduce weight and cost of cooled composite nozzle ramps. A lightweight actively cooled ceramic matrix composite (CMC) system would be lighter than metallic designs and would require significantly less cooling during re-entry. Composite Factory proposes a zirconium-silicate or Zr-Si-O glass CMC with integral ceramic tubes reinforced with a low cost discontinuous ceramic fiber preform. Integral ceramic composite mounting structure offers potential for a 2.0 lb/ft2 structurally integrated exhaust ramp. The Phase-I project proposes to demonstrate the feasibility of producing an ultra high temperature CMC based on the zirconium-silicate materials currently used in EBC coatings for SiC-SiC CMC's. Low cost pre-ceramic polymer CMC manufacturing methods combined with automated low-cost fiber preforming methods will be applied in order to keep both material and processing costs at a minimum. Mechanical test coupons will be fabricated and tested. Phase-II objectives would include design and fabrication of a sub-scale test component to verify durability of the composite structure along with manifolding and hermeticity of coolant channels. The development of a low cost zirconium-silicate matrix would be applicable to turbine engine combustor liners and other commercial engine exhaust components used to mix exhaust gas and reduce noise emissions.

Potential Commercial Applications:
Currently Composite Factory focuses on BlackglasTM based CMC components. Applications currently being produced for sale are the CMC brakes for motorcycle racing and after-market street use. We are currently working with multiple automotive OEM's to introduce the CMC brakes into automotive applications. The ability to offer a higher temperature polymer derived CMC system based on similar chemistry would increase the potential markets Composite Factory could pursue. Immediate markets for exhaust liners in diesel engines and combustor liners in turbine engines appear promising.The application of a higher thermal conductivity phase in the CMC may also improve the performance of the CMC as a friction material in aircraft brake applications where higher thermal conductivity is critical to maintaining acceptable surface temperatures.

NASA has identified a need to reduce weight and cost of rocket thrust chambers, nozzles, and ramps. A lightweight actively cooled ceramic matrix composite (CMC) system would be lighter than metallic designs and would require significantly less cooling. Composite Factory proposes a zirconium-silicate or Zr-Si-O glass CMC with integral ceramic tubes reinforced with a low cost discontinuous ceramic fiber preform. Integral ceramic composite mounting structure offers potential for a 1.2 to 2.0 lb/ft2 structurally integrated exhaust ramp, thrust chamber, or nozzle. The Phase-I project demonstrated the feasibility of adding Zr and tubes including nearly a two-fold improvement in flex strength. During Phase-II a more detailed material evaluation will be performed to determine the concentration of Zr required to improve the thermal stability of the CMC. Testing will include basic mechanical, cooled and un-cooled flat plates and cylinders in the Air Force LHMEL facility and thrust chamber and ramp testing at NASA Glenn. The development of a low cost zirconium-silicate matrix would also be applicable to military and commercial turbine engine components. Efforts related to helicopter turbine exit nozzles are being proposed to the Army in a related Phase I SBIR Topic (A01-079). POTENTIAL COMMERCIAL APPLICATIONS The efforts performed under the Phase I SBIR are complementary to current in-house research activities to expand the usage of Composite Factory's Shuttle Gate Preform Machine and to increase Composite Factory's CMC manufacturing capability. Currently under development is a second generation of motion controls and programming control for the Shuttle Gate Preform Machine with the goal to achieve more precise control with less operator intervention and higher outputs to handle the higher cost ceramic fibers with more precision and ever lower scrap rates. The use of the preform machine in CMC applications will reduce the cost of preforming and fabrication of most CMC's. The Preform machine is already a key part of Composite Factory's business plan and additional markets (CMC's) will continue to drive the costs of preform machines and preforms lower. Currently Composite Factory focuses on Blackglas based CMC components. Applications currently being produced for sale are the CMC brakes for motorcycle racing and aftermarket street use. We are currently working with multiple automotive OEM's to introduce the CMC brakes into automotive applications. The ability to offer a higher temperature polymer derived CMC system based on similar chemistry would increase the potential markets Composite Factory could pursue. Immediate markets for exhaust liners in diesel engines and combustor liners in turbine engines appear promising. The application of a higher thermal conductivity phase in the CMC may also improve the performance of the CMC as a friction material in aircraft brake applications where higher thermal conductivity is critical to maintaining acceptable surface temperatures. It is Composite Factory's business to produce polymer and ceramic matrix composites for commercial applications and any technology that opens additional markets