Low Cost Net-to-Shape Fiber Preforms for Complex-Shaped CMCs.

This Phase II NAVAIR SBIR Program seeks to demonstrate the real CMC component fabricability and scale-ability for complex shaped JSF turbine engine components such as a blade, vane, and/or shroud, using the MATECH GSM (MG)-developed low-cost “Net-to-Shape”TM SiNC fiber pre-forming techniques. MG will further explore pure NTS in order to improve thermo-mechanical and impact-resistance behavior of sub-component coupons. In parallel studies, MG will examine Hybrid-NTS for demonstration of complex-shaped component fabricability, and at the same time for improved CMC performances. “Net-to-Shape”TM SiNC CMCs are a unique new class of material system combining high temperature capability, low cost production potential, more pseudo-isotropic properties, complex shape capability, and high creep/rupture resistance suitable for gas turbine engine applications at >2600F. During the Phase I program MG’s technical staff designed and fabricated a complex-shape generic vane-shape component, and tested as-fabricated strength on its witness flat panel using our NTS SiNC fiber pre-forms and PIP densification process. Key achievements during the Phase I program were 1) the optimization of synthesizing conditions for melt-blowable SiNC pre-ceramic polymers, 2) defining the melt-blowing parameters, 3) fabricating a variety shape of non-woven pre-forms, and 4) successfully densifying them with a residual porosity of <10%.