Joining of Ceramic Composite Materials
Small Business Information
1375 Folkstone Ct, Ann Arbor, MI, 48105
David R. Treadwell
AbstractCeramic/ceramic composites are high performance structural elements in many military and commercial applications. Cost-effective methods of producing mechanically strong bonds between ceramic composite components during fabrication of complex shapes are critical to achieving next generation performance targets for both industrial (automotive) and military (aerospace) applications. Existing materials for bonding ceramics are often difficult to process, produce CTE mismatches in the joint, and poor load transfer between components, resulting in poor thermomechanical properties. The development of novel bonding materials is key to fabricating complex ceramic shapes for which machining is either impossible or prohibitively costly. Further complications arise in joining composite materials; where microstructural continuity must be preserved to preserve composite mechanical properties. In Phase I, Tal Materials, Inc. proposes to assess the utility of low-cost polymer precursors to phase pure, fully dense silicon carbide (primary emphasis), as "glues" to develop cost-effective methods of joining nonoxide ceramic/ceramic particulate (emphasis) and fiber composite components. This approach relies on the facile conversion, in high ceramic yield, of preceramic polymers to amorphous and then crystalline ceramics at 600--1200-C, well below temperatures typically required to form or join ceramics via melt processing or hot pressing. The goal is to identify preceramic polymers that can be used successfully to join a select set of nonoxide (e.g. AlN)/SiC particulate and SiC fiber composites, while maintaining the desired properties. The proposed precursor polymers will provide an effective, inexpensive approach to mechanically strong joints between ceramic composites. The demonstration of the utility of inexpensive, processable ceramic precursors for producing dense, controlled microstructure (low porosity), strong joints for composite components. If successful, the developed methods offer inexpensive processing of ceramic joints with controllable microstructure for a variety of military and commercial applications: light-weight armor, heat exchangers in nuclear (and fusion) power plants, jet/rocket exhausts and r
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