Low Cost Three-Dimensional Reinforced Ceramic Matrix Composites (CMCs)

The objective of this study is to define and demonstrate low-cost 3-D ceramic matrix composite (CMC) architectures and associated manufacturing processes for application to advanced military aircraft (such as the JSF) gas turbine engine components. Three-dimensional architectures offer the potential for increased durability by enhancing interlaminar and through-thickness mechanical properties. However, ineffective and inefficient processing issues need to be resolved. Overall the effort needs to properly consider and balance the effects of the three-dimensional architecture and its associated manufacturing processes, in terms of fiber integrity and adequate densification, to achieve affordability and durability benefits. In the initial phase, the feasibility of the low-cost three-dimensional architecture and manufacturing processes will be demonstrated via fabrication and testing of coupon specimens of selected candidate 3-D CMC's. Alpha STAR's commercially available GENOA software, a verified analytic/design tool, will be utilized to: accurately predict the 3-D CMC service lifetimes; predict their inspection, repair, and maintenance intervals, and optimize the 3-D architecture/manufacturing processes for durability, damage tolerance and low cost manufacturability, thus producing a better, low-cost 3-D CMC product. Successful demonstration/verification of a life prediction analytical methodology for low cost three-dimensional ceramic composites would reduce future certification costs of any advanced engine CMC structures.