A Laser-Assisted Machining Approach for the High Performance Machining of CMCs

Ceramic matrix composite (CMC) materials are desirable for high performance missile components due to their excellent strength-to-weight ratio and their ability to withstand high temperatures. However, CMC materials are expensive to machine due to their low thermal conductivity, high hardness, and abrasiveness. Creare’s innovation is a novel Laser-Assisted Machining (LAM) system for high performance machining of CMC components. Our novel processing technique uses a laser to preheat a thin layer of the CMC material prior to its removal using conventional machine tools. By using the laser-assist, the cutting forces during machining are reduced, which enables the production of high quality, defect-free parts at increased processing speeds. During the Phase I project, we assembled a proof-of-concept LAM system, completed machining tests on CMC parts, generated a preliminary scaled-up system design that can be integrated into our commercialization partner’s machine tool, and demonstrated the cost savings. During Phase II, we will finalize the system design and complete the integration and full-scale testing. This will be followed by technology transition and commercialization.