Manufacturing of Advanced Composites for Selected Propulsion Components

Advanced CMC composites are currently being developed for various components in the propulsion system along the hot gas path, where pressures up to 3000 psi and flame temperatures from 4000 degrees F to 5000 degrees F are encountered. In order to achieve the lightest possible and optimal component design meeting both structural and high temperature operational requirements, both fiber preform and matrix material selections are critical. While the selection of matrix materials based mainly on material"s stability and ablation resistance at severe temperature is relatively straight forward, the creation of optimal fiber reinforcements is more complex. In addition to fiber selection and fiber placement, the practical manufacturing limitations are also important considerations. An optimized fiber preform should use the best fiber, oriented in the load direction and is producible. Imported needled fiber preform has been selected as a baseline for many CMC components. Needled preform typically offers low but relatively isotropic fiber distribution. They were originally developed and optimized for A/C brake and exit cone applications. These preforms are costly and require long lead time. Under this program, plan is proposed to develop domestically produced needled preform with optimized design for CMC composites allowing end user/ material designer to develop the best CMC composite achieving the lightest possible component design at affordable cost.