Ceramic Field Repair for Structurally Compliant, Dielectric Matched Component Restoration

ABSTRACT: In this AF Phase II SBIR program, MATECH proposes to further demonstrate the ability to perform"on wing"repair of ceramic matrix composite (CMC) components. On wing repairs cannot exceed 300F cure temperatures. MATECH proposes to demonstrate its high ceramic yield, fully domestic, solvent less preceramic polymer resins, as the preferred resin system for field repair. These resins can be fully cured at below 300F, thereby meeting the on wing temperature requirement. This resin also emits limited gaseous by-products during curing. Higher temperature"pyrolysis"can be performed either by utilizing engine heat (for engine and exhaust components) or in flight (for leading edge components). In the Phase I, MATECH demonstrated this approach by measuring CMC strength before and after the simulated repair of"near catastrophic"matrix damage in a large scale CMC system. The damaged CMC flexural strength and modulus properties were fully restored to equal (and above) those of the'as received'CMCs. The technique used for the simulated repair will be amenable to an operational field application environment (flight line or hanger). This Phase II program benefits from the active support and participation of Lockheed Martin(Fort Worth, TX), GE Aviation (Cincinnati, OH), and General Atomics (San Diego, CA). BENEFIT: Ceramic and ceramic matrix composite will be increasingly utilized in both military and commercial aircraft engines and turbine generators, along with other applications requiring high service temperature components, due to their light weight and higher service temperature capabilities. A facile, user friendly ceramic repair capability would greatly encourage the use of ceramics and CMCs in commercial applications by reducing maintenance costs.