Development of Laser Fusion Coatings for Improving Oxidation Resistance of C/C Composites

Not Available For many BMDO, DoD, electronic packaging and aerospace applications under consideration, both pressure cast and reaction infiltrated discontinuously reinforced aluminum, DRA, composites are candidate replacements for more traditional materials and graphite epoxy composites. However, the high costs associated with difficulty in fabricating prototypes and small production runs presents significant barriers. Selective Gelation Printing, SGP, is an innovative solid freeform fabrication technology that can directly create very high quality preforms from CAD-generated solid model, thereby eliminating non-valued added steps and part specific tooling. This increased flexibility will enable rapid design changes, dramatically reducing cost and lead time involved in developing and fabricating DRA parts from months to weeks. DRA materials can be designed and synthesized with novel microstructures such as functionally gradient compositions. Phase I will build the alpha SGP system and establish feasibility in building porous ceramic preforms with specifiable volume fraction. Test articles will be characterized for dimensional accuracy, homogeneous particle distribution, and volume fraction and to verify cost performance benefits. Phase 2 goals include developing fully integrated beta SGP system capable of faster build times with expanded preform material and design capability. Also integrate computer modeling and simulation for process control, materials and preform design.