Processing of High-Strength Thick C-C Composite Structures using a One-Step Process

Some aerospace vehicles components require structural materials with temperature stability near or above 3000?F. Carbon-carbon (C-C) composites are prime materials for these applications because of their unique properties. Current C-C composites fabrication techniques are very expensive and time consuming. They usually require multiple infiltration and carbonization at high temperatures. Thick C-C composites further complicate the processing procedures and are a challenge to achieve property uniformity and reliability. In our previous SBIR researches we have successfully processed a new class, low-cost carbon/graphitic microcellular C-C composites from mesophase pitch and carbon fabrics using a one-step process. In this proposed project we will replace the microcellular pores with dense carbon matrix to become thick C-C composites. With the addition of our proprietary nanomaterial the oxygen stabilization time was greatly reduce to between 0 and 2 hours. The thick C-C composites developed in this project will have improved strength and modulus, properties uniformity, improved oxidation resistance, zero thermal expansion coefficients, manufacturing reliability, and good thermal conductivity. Various mechanical tests will be performed to characterize the properties of the C-C composite laminates fabricated. The proposed fabrication technique will significantly reduce the cost and manufacturing time of the C-C composite structures.