Sapphire Optical Fiber Sensors for Intelligent Low-Cost Processing of Tritanium Matrix Composites

The objective of the proposed SBIR program is to develop and commercialize high-temperature optical sensors using sapphire fibers for process control feedback in the fabrication of titanium-based metal matrix composites. Sapphire fiber interferometers will be designed to map the internal distribution of strain and temperature in titanium matrices durng processing, to optimize processing so that reliable, unifrom parts may be manufactured at low cost with high yields. Optical fiber sensors developed by Fiber and Sensor Technologies have been used for the intelligent processing of ceramic actuators for the ARPA "Smart Materials and Structures" program, and similar sensors have been embedded in ceramic matrix composites fabricated by chemical vapor infiltration at the Oak Ridge National Laboratory. The principal investigators were responsible with several aerospace manufactueres for pioneering research involving the integration of opticla fiber sensors with titanium matrix composites. The proposed program will build upon that initial work to confirm the feasibility and survival of improved sensors during solid state and liquid phase processing. Virginia Tech will serve as a subcontractor to assist with sensor development. State and local cost-sharing has been pledged. Dual-use applications of the high temperature sensor instrumentation systems are documented. Anticipated Benefits: High temperature optical fiber sensors may be used for the proposed applications of advanced composite materials manufacturing, as well as in dual-use applications including the instrumentation of high temperature power generation, the internal analysis of components in jet and internal combustion engines, and the fabrication of conventional metals and chemicals.