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

这个小型企业创新研究计划(SBIR)第二阶段项目利用一种独特的光固化、高重量产率的陶瓷前驱体聚合物在连续制造过程中生产低成本的β-碳化硅(SIC)陶瓷复合材料。第一阶段成功地完成了一种新型聚合物的光固化和冷引发快速固化(5分钟)，具有比预期更高的陶瓷产率、更容易的加工性和更大的可伸缩性。第二阶段将优化新聚合物的“按需固化”和粘弹性体积压缩，以增加陶瓷基质密度并消除织物层之间的聚合物回弹。预浸料技术的使用将使大片和大卷织物能够浸渍和固化成橡胶涂层织物-聚合物主体，可以很容易地存储、裁剪成图案，并在逐层工艺中应用。过程机械将扩大规模，通过快速固化和自动化零件制造来生产感兴趣的部件尺寸。潜在的商业应用预计将在气体循环风扇、热交换器、辐射燃烧器屏幕和管、燃气轮机燃烧衬里和尖端护罩、热液体过滤、安全壳、燃气熔化浸没式燃烧器管和炉管吊架中应用。最终，可以为高超声速飞机等飞行器建造大型复合材料结构。

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.