Increase Yield Production of Carbon/Carbon Composites via Machining Optimization

In this program, the proposer will develop a cutting-edge physics-based modeling and process optimization technology for enabling automated, high-quality machining of Carbon/Carbon (C/C) composites components with grinding tools. The goal is to replace trial-and-error approach with first-principle modeling, ensure first-part-correct production, dramatically reduce scrap and rework, and improve part quality. This technology will facilitate the automation of C/C production, increase throughput and overall yield, and help create a stronger, broader supply base for C/C to meet current and future USAF and Department of Defense (DoD) hypersonic weapon systems' requirements. The prospective customers of the proposed technology include the USAF and DoD prime contractors for hypersonics and their C/C supply chain, as well as other defense and commercial C/C part manufacturers, and Ceramic Matrix Composites (CMC) and Polymer Matrix Composites (PMC) part manufacturers since the underlying technology is applicable. In Phase I, the proposer will engage with pre-identified customers, C/C manufacturers and DoD prime contractors for hypersonics to get customer buy-in, demonstrate the feasibility of the approach, and develop the business case and road map for Phase II.