SBIR Phase II: Continuous SiC Matrix Composite Fabrication Using UV Curable Precursors

Matech Advanced Materials, Westlake Village CA

Investigators

Abstract

This Small Business Innovative Research Program (SBIR) Phase II project utilizes a unique photo-curable, high weight-yield preceramic polymer in a continuous fabrication process to produce a low-cost beta-silicon carbide (SiC) ceramic composite. Phase I succeeded in both photo curing and cold-initiation rapid curing (5 minutes) of a new polymer with higher ceramic yield, easier processability, and greater scalability than anticipated. Phase II will optimize the new polymer for both 'cure on demand' and viscoelastic volumetric compression in order to increase ceramic matrix density and to eliminate polymer springback between fabric layers. Use of pre-preg technology will enable large sheets and rolls of fabric to be impregnated and cured into a rubbery, coated fabric-polymer body that can be easily stored, cut to pattern, and applied in a ply-by-ply process. Process machinery will be scaled up to produce component sizes of commercial interest with fast curing and automated part fabrication. Potential commercial application are anticipated in gas recirculating fans, heat exchangers, radiant burner screens and tubes, gas turbine engine combustion liners and tip shrouds, hot liquid filtration, containment shells, gas-fired melting immersion burner tubes, and furnace pipe hangers. Ultimately, large composite structures may be constructed for vehicles such as hypersonic aircraft.