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Additive Manufacturing of SiC-SiC CMCs

Award Information
Agency: National Aeronautics and Space Administration
Branch: N/A
Contract: 80NSSC19C0416
Agency Tracking Number: 193499
Amount: $124,999.00
Phase: Phase I
Program: SBIR
Solicitation Topic Code: A1
Solicitation Number: SBIR_19_P1
Timeline
Solicitation Year: 2019
Award Year: 2019
Award Start Date (Proposal Award Date): 2019-08-19
Award End Date (Contract End Date): 2020-02-18
Small Business Information
7800 South Nogales Highway
Tucson, AZ 85756-9645
United States
DUNS: 066066874
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: Yes
Principal Investigator
 Zachary Wing
 (520) 547-0861
 zwing@acmtucson.com
Business Contact
 Morris Hicks
Phone: (228) 813-6325
Email: Morris.hicks@nasa.gov
Research Institution
N/A
Abstract

SiC-SiC ceramic matrix composites (CMC) offer significantly lower density and higher resistance against high temperature oxidation than conventional materials. They are widely used in aerospace and energy production industry in shrouds, combustor liners, blades, jet tabs and vanes, blast tubes, and nozzle throats. CMC use in aircraft engines is projected to double over the next five years.It is necessary to reduce the cost of SiC-SiC CMC production and to increase durability of CMC components. There are different SiC-SiC CMC fabricating technologies, each of which has its advantages and disadvantages. Melt infiltration approach provides the greatest opportunities for commercialization/mass production, but it suffers with a drawback of residual free silicon, which invariably remains in the matrix, volatilize at high temperatures and form cracks. The excessive silicon may also react with environmental water vapor resulting in deterioration in service properties. All production methods are time and labor consuming and thus, expensive.It is proposed to use laser assisted additive manufacturing (AM) process to build layer by layer near net shape preform 3D structures as well as to implement laser assisted AM infiltration of a SiC + C preform with molten silicon. It is also proposed to almost fully eliminate free silicon in SiC-SiC CMC by bonding Sifree into compounds with high energy of formation. Silicon carbide fabric/carbon preform will be infiltrated with the alloyed silicon melt which results in dense SiC matrix targeting free silicon content of le;0.5%. The compositions of the preform and infiltrating melt will be optimized by analyzing the microstructures and phase compositions and by measuring density, flexural strength and fracture toughness of the consolidated CMC. Mechanical properties will also be measured after temperature aging tests.

* Information listed above is at the time of submission. *

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