SBIR PHASE I: Combustion Chemical Vapor Deposition Processing of Lanthanum Phosphate and Beta-Alumina Fiber Coatings for Mullite Matrix Composites

*9561712 Hunt这个小型企业创新研究第一阶段项目将展示燃烧化学气相沉积(CCVD)以低成本沉积用于复合材料应用的高质量磷酸镧和β-铝酸盐薄膜的能力。将进行一系列运行研究，以优化工艺并证明其重现性。在这个项目中，将使用CCVD在平板衬底和纤维上生长磷酸镧和β-氧化铝薄膜。薄膜的成分、形貌、微结构和机械性能将作为沉积条件的函数来确定。燃烧化学气相沉积(CCVD~M)是目前唯一一种适用于陶瓷材料的开放式CVD技术。CCVD方法已被证明以连续的方式廉价和快速地应用致密、附着的外延薄膜。该技术可用于生产磷酸镧和β-铝酸盐涂层热结构复合纤维，以提高莫来石基复合材料的稳定性和增韧性能。CCVD方法具有成本低、质量高、通用性强等特点。它不需要反应室或炉子，但所生产的薄膜在质量上与CVD薄膜相当，并允许纤维轻松通过沉积区，以实现多层生产线涂层。这家公司已经在开放的大气中使用CCVD生产了多种材料的CVD质量薄膜。这使得处理纤维丝束变得容易，这是其他现有涂层技术的主要问题。传统的陶瓷纤维CVD涂层速度慢、难度大、成本高，而且需要专门设计的炉子。相比之下，CCVD技术能够在不需要专门设备或环境的情况下涂覆多根纤维。一家大公司已经表示有兴趣在纤维上生产低成本、高质量的磷酸镧和β-铝酸盐薄膜，用于莫来石基复合材料的高温防护和结构复合材料。出于这些原因，CCVD技术非常适合用于开发用于风扇叶片、气缸插件、刹车转子和相关应用的复合材料。***

*** 9561712 Hunt This Small Business Innovation Research Phase I project will demonstrate the ability of Combustion Chemical Vapor Deposition (CCVD) to inexpensively deposit high quality lanthanum phosphate and beta-aluminate thin films for use in composite applications. A series of run studies will be performed to optimize the process and demonstrate reproducibility. In this project, thin films of lanthanum phosphate and beta-alumina will be grown onto flat substrates and fibers using CCVD. The composition, morphology, microstructure, and mechanical properties of the films will be determined as a function of deposition conditions. Combustion Chemical Vapor Deposition (CCVD~M) is the only open atmosphere CVD technique for ceramics. The CCVD method has been shown to inexpensively and quickly apply dense, adherent, epitaxial thin films in a continuous manner. This technology can be used for the production of lanthanum phosphate and beta-aluminate coated thermostructural composite fibers for stability and toughened behavior in mullite matrix composites. The CCVD method is low cost, high quality and versatile. It does not require a reaction chamber or furnace, yet the thin films produced are comparable in quality to CVD films, and allows fibers to be easily passed through a deposition zone for multi-layered, production line coatings. This firm has produced CVD quality films of numerous materials using CCVD in the open atmosphere. This allows for easy handling of fiber tows which is a major problem for other existing coating techniques. Traditional CVD coating of ceramic fibers is slow, difficult and expensive, and requires a specially designed furnace. In contrast, the CCVD technology offers the ability to coat multiple fibers without specialized equipment or environments. A large corporation has expressed interest in this technique for the production of low cost, high quality lanthanum phosphate and beta-aluminate films on fibers for high temperature protective and structural composites in mullite matrix composites. For these reasons, the CCVD technology is well-positioned to be used in the development of composites for fan blades, cylinder inserts, brake rotors and related applications. ***