Modeling and Simulation of Ceramic Matrix Composite (CMC) Processes

ABSTRACT: Innovative research and development leading to a dual-use advanced technology product is proposed. The product is a physics-based methodology and associated software for a analytical model to simulate the manufacturing process for Ceramic Matrix Composites (CMCs). Once developed and validated, the methodology would be used in the cost effective development of CMC components by the Air Force and its major CMC suppliers. The proposed methodology would be applicable to a broad class of CMCs and components for military and commercial applications. The approach includes direct consideration of relevant mechanisms involved in the Polymer Impregnation and Pyrolysis (PIP) process for CMCs, whose modeling is of immediate interest to COI Ceramics, Inc. (COIC), who along with United Technologies Research Center are our industry endorsers. Phase I will include modeling of specific stages used in the PIP process using existing data obtained from COIC under subcontract, and quantification of material properties with the goal of satisfying a set of target properties for the composite. The models will be validated against benchmark test data and predictions will be compared with experimental measurements in order to assess the modeling approach and feasibility for a more comprehensive methodology development in Phase II. BENEFIT: Due to the proliferation in potential applications of Ceramic Matrix Composites in military and commercial aerospace engines and in industrial gas turbine industries, the proposed dual-use high technology product has an immediate and expanding market. SAI will market the methodology, the software and technical expertise (services) to CMC manufacturers and other the end-users of CMC materials.