TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: F-35 - Joint Strike Fighter, ACAT I

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: Develop methodologies to support innovative manufacturing process development to ensure optimized CMC component fabrication.

DESCRIPTION: The Joint Strike Fighter and other military systems are considering the use of CMC�s for propulsion applications. The materials are exposed to several densification and cure cycles during processing. Special precautions need to be taken during the densification process to ensure that the parts do not warp and twist during processing even through the fabric architecture is mid-plane symmetric. Additionally when fabricated components are subjected to engine operating conditions, the components may exhibit permanent deformation in the form of warping or twisting. This warping and twisting can be a direct result of a build up of residual stresses that are processing induced, depending on the part geometry. Permanent deformation to these critical components may result in premature failure and/or require premature replacement. Innovative approaches are required to supplement the manufacturing process to ensure proper component fabrication.

PHASE I: Develop a methodology that will provide for the optimization of the critical CMC processing procedures. Demonstrate the feasibility of the approach through the fabrication of a limited quantity of specimens.

PHASE II: Fully develop the approach into a manufacturing process tool. Provide sufficient verification and validation through manufacturing trials to enable a transitionable product.

PHASE III: Expand the technology for other materials, environments, and structural applications.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The technology developed here will be applicable to the chemical processing industries that utilize high temperature CMC systems.

REFERENCES:
1. Richardson, George Y., and Singh R. N. "Influence of Turbine Engine Environment on the Mechanical Properties of Ceramic Matrix Composites." Proceedings of the 34th International SAMPE Technical Conference, Baltimore, MD., Nov 2002.

2. Staehler, James M., and Zawada, Larry P. "Performance of Four Ceramic Matrix Composite Divergent Flap Inserts Following Ground Testing on an F110 Turbofan Engine." J. Am. Cer. Soc. Vol. 83, No. 7, 2000.

3. Lee, S. Steven, Zawada, Larry P., Staehler, James M., and Folsom, Craig A. "Mechanical Behavior and High Temperature Performance of a Woven Nicalon/Si-N-C Ceramic Matrix Composite." J. Am. Cer. Soc. Vol. 81,
No. 7, 1998.

KEYWORDS: Ceramic matrix composites (CMCs); processing; fabrication; propulsion; manufacturing; densification.

** TOPIC AUTHOR (TPOC) **

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