Modeling and Simulation for Robust Ceramic Matrix Composite (CMC) Manufacturing Processes

Increasing the power density of current jet aircraft engines requires the replacement of conventional high temperature materials by new materials capable of operating at higher temperatures. Ceramics and ceramic matrix composites (CMCs) represent excellent candidates for increased use in hot engine parts due to their ability to withstand temperatures in excess of 2000 C. Due to the complexity of the manufacturing CMCs, limited guidelines exist that can readily transfer between different components. Consequently experimental approaches are needed to develop detailed manufacturing procedures. The extensive development time and budget needed for this approach can be significantly reduced if predictive design tools for the RMI process were available. This work will develop analytical tools to analyze the multiple interdependent physical phenomena of relevance for the manufacture of CMCs. The analyses will be integrated into a design tool capable of providing engineers with an environment to analyze the CMC manufacturing process thus reducing the need for iterative experimental approaches. Consequently, the costs associated with manufacturing critical CMC components will be dramatically reduced and provide engines with improved thrust and fuel efficiency while reducing emissions. BENEFIT: With this tool, designers of turbine components will reduce cycle time, increase part yield, and better define the process window for CMC manufacturing thereby increasing the use of CMCs. Increased use of CMCs in hot engine parts will improve thrust and fuel efficiency while reducing emissions. Additional benefits will include reduced cooling requirements, simplified component design and reduced weight of the supporting structure.