Affordable Manufacturing of Complex Shape Metal Matrix Composite Structures of High Speed Rotocraft

An affordable processing and 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. Solid freeform fabrication technology is used to directly tool ceramic molds geneated from CAD solid models, which eliminates 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 solid freeform fabrication will establish pressure infiltration casting as a new paradigm for affordable and timely manufacutring of near-net shape metal matrix composites and components. The proposed effort will demonstrate enabling technology by fabricating a fiber reinforced complex shape MMC component for advanced high speed rotorcraft applications. Anticipated Benefits: The enabling technologies to be developed under this Phase I program will provide affordatble processing and manufacturing technology for rapid production of lighweight, complex shapes MMCs for primary and secondary aircraft structural applications requiring a combination of high stiffness or high strength at low weight. This would include components subjected to vibration, cyclic loading, rotation such as shafts, struts, transmission casings, compressor blades, pump housings containing gears (for reduced gear and bearing wear).