Company
Portfolio Data
Back to Company SearchADVANCED CERAMIC FIBERS, L.L.C.
UEI: WE9NMNL1ZNB6
Number of Employees: 9
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
SBIR/STTR Involvement
Year of first award: 2014
7
Phase I Awards
4
Phase II Awards
57.14%
Conversion Rate
$1,393,821
Phase I Dollars
$5,565,660
Phase II Dollars
$6,959,481
Total Awarded
Awards
UHT Ceramic Yarn Manufactured From Silicon Carbide (SiC) Fibers
Amount: $899,996 Topic: N231-072
The ACF team is focused on developing and deploying a manufacturing process in which SiC/C fibers are fabricated into yarns capable of integration into traditional weaving or braiding systems used to produce high strength, high temperature ceramic matrix composites (CMCs). Yarns of short discontinuous SiC/C fibers originating from Stretch Broken Carbon Fibers (SBCF) will be key to this effort. ACF’s unique conversion process demonstrated in Phase I is not limited to SiC/C materials and is projected to accommodate other high temperature materials such as ZrC/C and Ta/C fibers and other base carbon fibers (PAN, Pitch, CNT) available from different source (see 3.0 Letters of Support). Using ACF’s conversion process demonstrated in Phase I, the manufactured yarn will have sufficient strength to interface with various weaving and braiding processes used in the construction of 2D, 3D and the more complex 4D CMC preforms and textiles. In addition, ACF’s unique MC/C yarns also incorporate a unique intrinsic interfacial debond layer that eliminates the costly interfacial coating process thereby allowing direct ceramic yarn fiber manufacturing use in composite materials. Composite materials can also include various carbides and boride matrix composite ceramics and fiber use metals, i.e. aluminum and titanium. ACF’s four major PII objectives are: (1) Produce a prototype system capable of kilograms / hour for SiC/C yarn with scaled improvements to include the manufacture of advanced ZrC/C and TaC/C based yarns for UHT applications; (2) Iterate/refine the manufacturing process to improve efficiency and yarn quality while concurrently expanding the lab scale capability to make specialty SiC/C yarns with different strength, thermal, modulus and electrical properties; (3) Conduct trial runs designed to connect fiber characteristics with the manufacturing process and the through mechanical testing, imaging, and analysis with our team members MSU (test & analysis) and CPP (marine & HT corrosion); and, (4) Provide specific SiC/C yarns in kilogram spools to SSP Navy for testing and evaluation of the processes. As portions of this effort may be classified, all work shall be conducted under SSP guidance. ACF Phase II includes a 24-month (BASE – 18 month and OPTION 6-month.)
Tagged as:
SBIR
Phase II
2025
DOD
NAVY
Enhanced Thermal, Mechanical, and Physical Properties of CMC's Through Novel Additives
Amount: $999,995 Topic: N22A-T019
The objective of N22A-T019 STTR PHASE is to enhance and optimize oxidation resistance and thermal, mechanical, and physical properties of ceramic matrix composites (CMCs) through computational-directed and validated design and the addition of additive(s) to the Ceramic matrix. Advanced Ceramic Fibers (ACF) and Montana State University (MSU) shall apply validated models, initially formulated in Phase I to be further developed in Phase II to the synthesis of advanced matrices and coatings, using as a baseline monolithic materials (no additives) for comparison to materials with additives in component sub-systems and complete EBC/CMC systems. We shall work in coordination with an appropriate original equipment manufacturer (OEMs) to also establish and execute a test plan that will provide sufficient data for preliminary assessment of design allowables for critical and relevant design requirements. These requirements will be developed in conjunction with an OEM and ONR. Test samples will be manufactured using forming methods such as pressure casting and plasma spray coating to achieve different testing geometries (as necessitated by uniformity and testing hardware requirements). In these tests lead by ACF and supported by team member MSU ) we shall determination effects of additives on oxidative performance in selected ceramic matrix materials including a broad range of thermal and mechanical property data, including: density, hardness and impact resistance, thermal conductivity, thermal expansion, tensile strength, modulus, creep, and creep rupture, and vibrational and dynamic fatigue. Using samples made by ACF test conditions shall include controlled stress, temperature, and time under environmental conditions, including simulated turbine engine by-products of combustion gases with and without sodium sulfate and water present. For simulated hypersonic conditions we shall test under controlled thermal stress, temperature and environmental conditions including impact tolerance against high speed water and dust. By the end of the Phase II, we shall ensure that the collected data will be available to initiate constituent modeling of modified CMCs with lifetime predictions of oxidation resistance and thermal-mechanical-creep performance up to 100 hours. This data shall also be available to the OEM(s) both following and participating in the program. ACF shall ensure using advanced inductive sample heating methods that thermal-mechanical-creep tests will reach up to 1000 hours at 2000°C or more in air.
Tagged as:
STTR
Phase II
2024
DOD
NAVY
UHT Ceramic Yarn Manufactured from Discontinuous Fibers
Amount: $239,975 Topic: N231-072
Our Navy has two critical goals for this project (1) reduction in supply chain risk and (2) need to open additional sources of ōfiberö for the NavyÆs future needs. Advanced Ceramic Fibers (ACF) will achieve these two goals by setting up a domestic supply chain for manufacture of fiber based yarn(s) made from different discontinuous fiber types including nanofilaments and micron diameter fibers. ACF is known as a unique manufacturing source for advanced ultra-high temperature (UHT) fibers with some fiber types at TRL6. N231-072 supports Hypersonics and Space Technology with the objective to develop a manufacturing process in which for example short discontinuousĀsilicon carbide (SiC) fibers can be formed into a yarn capable of integration into traditional weaving or braiding systems for the production of high strength, high temperature ceramic matrix composites (CMCs) as part of thermal protection systems. ACFÆs technical and management experience span the range from novel fiber manufacturoing to incorporaton into CMCs for turbine engine, hypersonics and space applications. We will achieve the project and objectives goals by 1. We shall adapt commercial yarn twist spinning machine used in forming continuous twisted fiber yarn strands from discontinuous micron diameter filaments (mm lengths) and in Phase II set-up a second yarn spinning machine for nano-filaments (100-500 nm lengths). ACF uses commercially available yarns (micron to nano-meter in diameter) in short and continuous forms for several going Phase II (government) and Phase III (client) projects. 2. We shall apply our patented fiber and manufacturing process to produce high temperature continuous and short SiC layered carbon (SiC/C) fibers (TRL6) and in Phase II include other metal carbide (MC/C) fibers and nano-filament s fibers with utility above 30000C. Our patents cover fibers & manufacturing of unique fiber CMC forms (Quad-XEÖ). "ACF extends the performance utility of carbon fiber for use in extreme environments"
Tagged as:
SBIR
Phase I
2023
DOD
NAVY
Development of Advanced Ceramic Matrix Composite Matrices to 2000 Degrees C.
Amount: $239,866 Topic: N22A-T019
Competitive, national security, and efficiency concerns provide an urgent need for ceramic matrix composite research and development, particularly for use in hypersonic and turbine engine applications. Thermal and mechanically-induced stresses in these structures limit speed, strength, and life-expectancy. Composite performance may be greatly enhanced through the use of novel additives, such as fibers, nano-particles, or interphase coatings and may enable a much broader use of composites in the aerospace industry. Offeror proposes a 6-month Base and 6-month Option project for the development of fabrication methods and the application of novel additives to ceramic matrix composite fibers. Fiber fabrication will be followed by testing and modeling for oxidation and creep resistance of the fibers (both with and without additives) for function at temperatures up to 2000°C. Project data will be compiled into detailed databases for future use in design and manufacturing of complex ceramic matrix composite components for DOD-related technologies and future commercial applications.
Tagged as:
STTR
Phase I
2022
DOD
NAVY
Innovative Approaches in the Design and Fabrication of 3D-Braided Ceramic Matrix Composite Fasteners
Amount: $1,990,518 Topic: N202-128
The aeronautical and space industries need new technologies in the design and fabrication of 3-Dimensional Ceramic Matrix Composite fasteners for mechanically attaching composite propulsion and structural components to metals, both on, and within, the aerostructure body. Novel fasteners must be able to withstand environmental challenges including extreme temperatures, corrosion (such as the affects from exposure to water, salt and engine-related chemicals), erosion, abrasion and the cyclic effects from mechanical vibration and thermal sources. In support of this objective, the Offeror proposes an innovative solution focused on 3D-braided ceramic matrix composite fasteners which will exhibit increased mechanical strength properties, resistance to crack-propagation, engineered thermal conductivity and a potential for long-service duty performance at ultra-high temperatures.
Tagged as:
SBIR
Phase II
2022
DOD
NAVY
High-Temperature, High-Payoff, 3D-Braided SiC Fasteners
Amount: $239,481 Topic: N202-128
The aeronautical and space industries need new technologies in the design and fabrication of 3-Dimensional Ceramic Matrix Composite fasteners for mechanically attaching composite propulsion and structural components to metals both on, and within, the aerostructure body. Novel fasteners must be able to withstand environmental challenges including extreme temperatures, corrosion (such as the affects from exposure to water, salt and engine-related chemicals), erosion, abrasion and the cyclic effects from mechanical vibration and thermal sources. In support of this objective, the Offeror proposes an innovative solution focused on 3D-braided ceramic matrix composite fasteners which will exhibit increased mechanical strength properties, resistance to crack-propagation, engineered thermal conductivity and a potential for long-service duty performance at ultra-high temperatures.
Tagged as:
SBIR
Phase I
2021
DOD
NAVY
Low-Risk Approach to High-Payoff Ultra-High Temperature Ceramic Matrix Composites
Amount: $124,884 Topic: Z10
As governments and commercial entities compete for opportunities to travel to Mars and throughout deep space, the need for more efficient engines, reduced launch weight and increased payload capacities are constantly being developed. NASA is re-engaging its interest in Nuclear Thermal Propulsion because of its promise to double the efficiencies of competing engine types and fuels including higher energy density, greater thrust, reduced weight and increased velocities. In order to achieve these benefits, the proposed Nuclear engines need to run at temperatures exceeding 2700 degrees Kelvin, which necessitates the use of fuel rods to contain and manage the flow of hydrogen being utilized as a propellant. Until recently, the available materials lacked the performance properties necessary for the utilization of Nuclear engines.Utilizing novel fibers, matrices and fabrication methods, the Offeror proposes the development of a new type of ceramic matrix composite specifically designed to meet the specifications and performance properties required for long-term use in Nuclear Thermal Propulsion engines. The Offeror#39;s proposed fuel rod and/or cladding will exhibit revolutionary refractory capabilities, reduced hydrogen permeability, radiation tolerance, low creep, high thermal and mechanical stability, retention of fission products and improved manufacturability. The potential advantages of Nuclear Thermal Propulsion can now be realized through the development of novel materials and advanced manufacturing processes by a U.S. supplier. nbsp;
Tagged as:
SBIR
Phase I
2020
NASA
Additive Manufacturing 3100F Nanolaminate Matrix for Turbine Engines
Amount: $249,665 Topic: 19a
Major manufacturers of stationary gas turbines for electrical power generation are studying the potential for using higher temperature and environmentally stable ceramic matrix composites (CMC) as engine components to improve turbine engine efficiencies. One manufacturer estimates that a simple 2% increase in efficiency would save more than $50MM over the life of one generator. Higher operating temperatures could dramatically improve the thermodynamic efficiency of gas turbine generators, saving 300 billion BTU a year in natural gas alone (a $1.3 billion dollars savings for utility customers) while meeting long cycle life requirements (greater than 100,000 hours). Another manufacturer suggests that a 2% efficiency improvement will reduce NOx emissions by 50% and other emissions equivalent to taking 10,000 cars off the road per year. In order to achieve these advancements, CMC materials and matrices will be required to be developed. Recent advancements in ultra-high temperature materials and manufacturing methods suggest a pathway toward development of new CMCs which can operate at high temperatures for extended periods of time without the brittleness and oxidation concerns which have plagued ceramics in the past. The Proposer proposes a SBIR Phase I project focused on the utilization of new reinforcing fibers, nano-materials and matrix having high thermal conductivity, increased mechanical strength properties, resistance to crack-propagation, and long life-cycle utilization. Furthermore, these materials will be developed for the high-rate production of turbine engine components using additive manufacturing methods. The proposed CMC and manufacturing methods will have significant impact in the turbine engine markets for both stationary electrical power generation and aerospace applications. These high-temperature materials could provide a pathway for development of rotating detonation engines and improvements in micro-turbines to generate on-board electrical power for cars, trucks, buses and aircraft, not to mention true distributed energy systems to generate electricity in every home or building and provide significant protections to the security of our electrical grid. These CMC innovations could dramatically improve technology developments in heat exchangers, hypersonics, nuclear fuels and safety.
Tagged as:
SBIR
Phase I
2020
DOE
MEMBRANES AND MATERIALS FOR ENERGY EFFICIENCY Subtopic: High Performance Conductors Reinforced Commercial Metals for Enhanced Electrical and Thermal Conductivity
Amount: $150,000 Topic: 12b
Major improvements in the electrical and thermal conductivity of metals used in conductors are needed to improve the energy efficiency and reliability of our national electrical power systems. These metals need to be stronger and more resistant to corrosion, oxidation and fatigue which reduce the reliability and lifespan of conductors and create high costs for maintenance, repair and replacement. Stronger aluminum and higher conductivity metals could dramatically decrease the amount of electricity lost in line transmission over long distances. Higher thermal conductivity can improve the load capacity of transmission lines and avoid damage caused by overheating. More efficient conductors can reduce the weight of wiring used in aircraft and motor vehicles, improving their load carrying capacity while saving fuel. These improved metals can also be used in heat exchangers making them more efficient, and lower overall demand for additional power generation even as our national consumption of electricity continues to increase. In Phase I, Advanced Ceramic Fibers propose to demonstrate the feasibility of using innovative, low cost, fiber- reinforced metal matrix composites to dramatically improve the strength, weight, system-life and conductivity of aluminum and steel used in a variety of power generation, transmission and distribution system components. This study will demonstrate, test, and report on various types of novel cast, extruded or forged fiber reinforced metal matrix composites to improve conductor strength, electrical and thermal conductivity, and reduce (or nearly eliminate) creep and permanent elastic deformation. Phase II and III will provide platforms for designing, fabricating, and testing specific components which may include High Voltage Transmission Conductors, conductor connectors, dead ends, heat exchangers and potentially, armor to protect distribution control centers and other critical utility structures. This same metal technology can be utilized in a wide variety of commercial applications to lightweight and strengthen metals used in aircraft and motor vehicles, building materials and nuclear power system components to name a few. The public will benefit from lower electricity rates and greater reliability of the electrical grid, including reduced maintenance, repair, and replacement of transmission lines and fewer costly and dangerous blackouts. Use of these metal composites can lightweight vehicles and aircraft improving load carrying capacity, improving fuel efficiency, and reducing harmful emissions. Aging infrastructure and increasing demands on electric power transmission and distribution systems underscore the need for more efficiency. A promising solution is the development of fiber reinforced metal composites that make transmission lines and components stronger and longer lasting, while also dramatically increasing the electrical load carrying capacity and reducing line losses.
Tagged as:
SBIR
Phase I
2016
DOE
Robust 2700 F MC/C Fiber Reinforced Matrices for Turbine Engines
Amount: $1,675,151 Topic: N141-074
Advanced Ceramic Fibers, LLC (ACF) completed the Navy SBIR Phase I Base Program and clearly demonstrated the feasibility of our approach to create a truly robust composite for turbine engines that exceeds the known boundaries for ceramic composites and the Navy performance objectives for this Topic. Our engineered materials approach involved in-depth background experience in ceramic matrix composites (CMCs), modeling and selection of materials to combine ultra-high temperature (UHT) alpha silicon carbide/carbon (a-SiC/C) fibers with a proprietary interphase debond layer with a silicon carbide ceramic matrix. These composite materials opened up an entirely new world of stronger, more stable, lightweight, UHT design opportunities that were previously unknown and makes further development efforts truly compelling. The development of 2700 degree F capable fiber reinforced ceramic matrix composites (FRCMC),with enhanced material performance in salt and moisture environments, is critical to achieving higher military turbine engine performance utility.
Tagged as:
SBIR
Phase II
2016
DOD
NAVY