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

该小型企业创新研究计划（SBIR）第二阶段项目在连续制造过程中利用独特的光固化、高重量产量的陶瓷预制体聚合物来生产低成本的β-碳化硅（SiC）陶瓷复合材料。 第一阶段成功地在光固化和冷引发快速固化（5分钟）的一种新的聚合物具有更高的陶瓷产量，更容易加工，更大的可扩展性比预期的。 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。 预浸技术的使用将使大的织物片和卷能够被浸渍和固化成橡胶状的、涂覆的织物-聚合物体，其可以容易地存储、切割成图案并以逐层工艺应用。 工艺机械将按比例放大，以生产具有商业利益的部件尺寸，并具有快速固化和自动化部件制造。预计潜在的商业应用包括气体再循环风扇、热交换器、辐射燃烧器屏和管、燃气涡轮机燃烧衬套和叶尖、热液体过滤、安全壳、燃气熔化浸没燃烧器管和炉管吊架。 最终，大型复合材料结构可用于高超音速飞机等飞行器。

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.