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）二期项目利用一种独特的光固化、高产量的预陶瓷聚合物，在连续制造过程中生产低成本的碳化硅（SiC）陶瓷复合材料。第一阶段成功地进行了光固化和冷启动快速固化（5分钟）的新聚合物，具有更高的陶瓷收率，更容易加工，以及比预期更大的可扩展性。第二阶段将优化新聚合物的“按需固化”和粘弹性体积压缩，以增加陶瓷基体密度，消除织物层之间的聚合物回弹。预浸技术的使用将使大片织物和卷织物被浸渍和固化成橡胶，涂层织物-聚合物体，可以很容易地储存，裁剪成图案，并在一层一层的过程中应用。加工机械将扩大规模，以生产具有快速固化和自动化零件制造的商业利益的组件尺寸。潜在的商业应用预计在气体再循环风扇，热交换器，辐射燃烧器屏幕和管，燃气涡轮发动机燃烧衬套和尖端罩，热液体过滤，容器壳，燃气熔化浸入式燃烧器管，和炉管吊架。最终，大型复合材料结构可能会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.