Agile Manufacturing of Fiber Reinforced Complex Shape Metal Matric Composites Structures with Application V-22

A novel agile manufacturing system for production of fiber reinforced complex shape metal matrix composites (MMCs) is proposed. The composites are precision cast by pressurized infiltration casting. Thin-walled ceramic molds are used to contain and infiltrate complex-shaped preforms. A powerful, user-friendly 3D graphics software package is used to interactively create mold designs from the solid model of MMC component to be cast. The software can also analyze the casting process in transient 3D to simulate mold filling. A rapid prototyping method directly creates ceramic molds from the CAD-generated solid model, eliminating intervening steps and part-specific tooling. This increased flexibility allows for rapid design changes, dramatically reducing the cost and lead time involved in casting complex shape MMCs. Computer integrated manufacturing incorporating rapid prototyping will establish pressure infiltration casting as a new paradigm for affordable and timely manufacturing of near-net shape metal matrix composities and components. The proposed effort will domonstrate enabling technology by fabricating a fiber reinforced complex shape MMC component for the V-22 Osprey tilt rotor.