Innovative Manufacturing Process for High Temperature Ceramic Yarn from Advanced SiC Fibers

In support of Navy Small SABIR Phase II High Temperature Ceramic Yarn from Discontinuous Silicon Carbide (SiC) Fibers, Applied Technology Solutions (ATS) proposes to build on the successful feasibility demonstrations of Phase I to produce yarn from short SiC fibers for hypersonic Ceramic Matrix Composites (CMC) and other Department of Defense (DoD) applications. Due to the brittleness, sensitivity to shear stress and lack of natural crimp in ceramic fibers, the processing of staple SiC into slivers, as well as yarns, is a challenging task compared to the conventional textile fibers.  This proposal outlines the plan to develop prototype yarn fabrication capabilities, refine and optimize the process, and demonstrate the benefits of the resulting yarn in a weave and SiC/SiC CMC, which will be characterized and tested in hypersonic flight representative environments. At the conclusion of Phase II, ATS will have developed and documented a one-of-a-kind capability for producing yarn from short ceramic staple fibers and will have completed initial steps into validating this technology for transition to the industry.