Sequential Laser Assisted Machining of Ceramic Materials

Physical Sciences Inc. (PSI) proposes to design, build and demonstrate a high speed machining processes for fabricating pockets and slots in ceramic matrix composite (CMC) materials using a sequential laser assisted machining (SLAM) process. The Phase I SBIR program successfully demonstrated the proposed machining processes that reduce tool wear by more than a factor of 100 compared to grinding processes for the same feature. The increased machining speed and lower costs for consumable tooling enable cost effective high volume production of complex CMC components with interlocking and guide features. This Phase II SBIR program will demonstrate SLAM processes for CMC that … 1) Can achieve precision tolerances for blind feature machining. 2) Can be used to machine precision depth slots for sliding components 3) Can be adapted to a production multi-axis machining center. 4) Can be transitioned to the fleet as an upgrade to existing CMC laser cutting systems During the Phase II program we will demonstrate the SLAM process on a CMC laser machining tool. The integrated tool will be validated by our partners at ABL, P&W, GE and Rolls Royce for CMC propulsion component production.