Improved Manufacturing Technologies for Polymer Matrix Composite Engine Components

This proposal addresses the development and use of lightweight, low thermal-capacity reformable tooling materials for high-temperature composite processing evaluation, parts prototyping, trial production and full-rate production of PMC engine components. The weight-saving promise of high-temperature polymer matrix composites (PMCs) for engine components is offset by the very high costs of parts manufacture. In processing polyimide-matrix composites to produce engine duct components, current tooling and methods require very long processing times. Optimized tooling would provide a ramp-up rate consistent with the heatup rate of the composite material, while providing the strength to withstand the process temperatures and pressures.