Technologies for Air Breathing Propulsion

"This proposal is to develop and demonstrate a concept for a light-weight/lower-cost integrated process for producing TMC aircraft engine LP shafts. Such shafts will significantly benefit propulsion systems of advanced fighter aircraft like the JSF. Theproposed integrated process will reduce the weight of a TMC JSF type LP shaft by approximately 30% relative to TMC shafts produced with the current TMC manufacturing approach and result in a final shaft (with nickel alloy ends) that is 20% to 25% lighterthan the current nickel alloy shaft. The proposed approach integrates advances in TMC design, tooling, assembly and processes to use a pre-consolidated (green) arrangement of fibers and matrix that is nearer to the net shape of the post-consolidated partand incorporates more positive separation of the silicon carbide fibers than is provided by the current approach. Process and tooling modeling and preliminary development show feasibility for the concept. Phase 1 will develop the concept, performanalyses and conduct subscale testing to demonstrate its feasibility. Modeling and simulation will guide the direction. Phase 2 will provide detailed analytical derivations and prototypical device demonstrations and will develop a technology transitionplan for future systems and commercial ventures. The effort will establish an improved integrated process for the production of titanium matrix composite reinforced LP shafts. Shafts produced