Multiscale Modeling for Melt Infiltration Process in Ceramic Matrix Composite (CMC) Manufacturing

CFDRC proposes to develop a comprehensive, high-fidelity commercial quality simulation tool for modeling the melt infiltration process in Ceramic Matrix Composite (CMC) manufacturing. The code will accurately predict the transient melt infiltration process with tightly-coupled detailed physics-based component-level and micro-scale models for the infiltration front and solidification in the porous preform. The foundation for this tool will be the proven multi-physics CFDRC code. In Phase I, we will demonstrate feasibility of simulating melt infiltration processes at the component level through submodels for capillary transport in porous media coupled with reaction kinetics and associated temperature and volumetric changes. In Phase II, we will improve the scope, speed and accuracy of the tool using a novel multiscale modeling approach. Tightly coupled pore-scale multiphase simulations will feed into component-level models with advanced numerical tools unique to CFDRC. These advanced tools include free surface modeling with capillary forces and variable viscosity, surface reactions and heat interactions, particle tracking, parallel processing, and stochastic solvers based on Lattice-Boltzmann and Kinetic Monte-Carlo methods. These capabilities will be coupled and integrated into a user-friendly software package. The development will be performed in close collaboration with Goodrich, a leading CMC provider, to insure relevance and facilitate technology insertion.