High Tolerance Component Braiding

Physical Sciences Inc. (PSI) will demonstrate a manufacturing approach for the production of high tolerance carbon/carbon components. PSI will pre-preg tape braid two complex components to demonstrate process repeatability. Each component will be processed through carbonization. A coordinate measurement machine (CMM) and CT scanner will be used to measure and inspect each component in the cured and carbonized state. We will demonstrate that tolerances can be held to +/-0.020î in thickness and +/- 0.010î in circularity. We will work with Materials Research & Design (MRD) to predict fully dense carbon/carbon mechanical properties based on as-manufactured ply architecture supplied by PSI. Predicted properties will be compared to the state of the art to ensure sufficient performance in the anticipated operating environment. During the Phase I option period PSI will densify one of the manufactured components from the Phase I base. Measurements will be collected via CMM before and after densification and a final CT scan will be conducted at full density. PSI will compare final part tolerances to desired ranges and produce a report of all dimensional changes throughout processing. In a Phase II effort PSI will scale up manufacturing to demonstrator size and demonstrate tight tolerancing on full scale aeroshell structures.