Modified Resin Transfer Molding for Fiber Reinforced Ceramic Matrix Composites

The proposed Phase I SBIR program will demonstrate a simple, reproducible, cost-effective and near net-shape approach to "transfer molding" of advanced fiber reinforced ceramic matrix composites using a revolutionary and entirely new process developed by scientists at Triton Systems, Inc. We have already successfully demonstrated the feasibility of this unique process. The proposed effort will expand this technology to better understand it's processing parameters and optimize this technique in terms of mechanical, physical and thermal performance of the final composite. The result will be complex-shaped, fiber reinforced CMC's which are designed to outperform CMC's processed by alternative processes. Our approach is based on "Resin Transfer Molding" (RTM) of organic matrix composites (OMC) which has been in use for several decades as a lower-cost alternative to autoclave curing and other labor and capital intensive processes used in high performance applications. The main advantages of this process are it's ability to deliver near-net-shape complex shapes in high volume and low cost with good surface topography. Other advantages include flexibility in tooling and materials, easy part consolidation through molded-in parts and fittings, fast production cycles and less than 2 percent voids. The Phase I program will optimize the process conditions, fabricate and characterize several fiber reinforced CMC specimens using a "Ceramic Transfer Molding" technique. The Phase II program will optimize the process for maximum strength, toughness and high temperature performance.