Sequential Laser Assisted Machining of Ceramic Materials

Physical Sciences Inc. (PSI) proposes to develop a high speed sequential laser assisted machining process for silicon carbide ceramic matrix composites. An integrated laser/high speed contact machine tool is envisioned to minimize component set-up time and abrasive silicon carbide debris. The tool achieves these goals using a laser based process for rough machining followed by high speed contact machining to finish machine through and blind features. The goal of the Phase I SBIR is to demonstrate the feasibility of a high speed, low cost laser assisted machining process for silicon carbide ceramic matrix composites that 1)Can machine features in silicon carbide CMCs with high precision. 2) Increases contact tool life by 100 times. 3) Does not degrade the mechanical strength of the machined part. 4) Can be scaled-up into a production capable machining platform. During the Phase I project we will demonstrate the feasibility of the laser assisted machining process by machining holes, slots and pockets in silicon carbide ceramic matrix composite panels. We will show that the minimal damage induced in the CMC enables the mechanical strength of the material in the machined component to be the same as that of the as fabricated composite.