Development of materials and processes for manufacturing ceramic matrix composites

Citation

(2009), "Development of materials and processes for manufacturing ceramic matrix composites", Aircraft Engineering and Aerospace Technology, Vol. 81 No. 4. https://doi.org/10.1108/aeat.2009.12781daf.009

Development of materials and processes for manufacturing ceramic matrix composites

Article Type: Mini features From: Aircraft Engineering and Aerospace Technology: An International Journal, Volume 81, Issue 4

Alliant Techsystems has received multiple contract awards from the ManTech Program office of US Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio to continue development of manufacturing process improvements for ceramic matrix composite (CMC) components. The contracts are valued at nearly $10 million and the awards have spanned 2007 and 2008. ATK is leading teams based on project specific requirements.

ATK expects aircraft engine manufacturers to incorporate CMC materials into next-generation aircraft to reduce both weight and life cycle costs. CMCs withstand the extreme temperatures of the engine exhaust stream better than existing materials and they can last up to three times longer. By using CMCs for engine components the US Air Force and US Navy can extend the time between engine overhauls, which significantly reduces aircraft maintenance costs.

ATK’s Rocket Center, West Virginia facility is leading a team examining improvements to the CMC Machining and the Matrix Densification Processing. The CMC Machining program team, which includes ATK, General Electric CCP and Goodrich High Temperature Composites, is a collaborative program to develop processes for cutting the extremely hard CMC material with lasers, water jets, mills, ultrasonics, and high-speed machining. The collaborators include the three CMC manufacturers as well as the engine original equipment manufacturers, General Electric, Rolls Royce and Pratt & Whitney. Additionally, the Matrix Densification Program requires the scale-up of the densification processes to reduce the cycle times and manufacturing costs.

ATK’s San Diego facility is leading teams established to improve the Resin and Fabric Optimization (R&FO) and the Production Fabric Coating ManTech Programs. The R&FO program is examining ways to improve the resin process yield while reducing cost and waste stream volume at the resin manufacturer. Additionally, during the R&FO program, utilisation of the ceramic fabric will be improved to reduce costs and waste. The Production Fabric Coating program is seeking ways to improve the manufacturing process and reduce the cost of coating ceramic fabrics.

The CMC products that ATK will manufacture are intended to be used initially in the jet engines of the F-35 Lightning II Joint Strike Fighter. ATK CMC materials could also be used in jet engines for other military and commercial aircraft.

ATK currently manufactures the seven-piece upper wing skin, lower wing skins, engine nacelle skins, and the upper wing strap for the F-35 Lightning II using advanced automated fiber placement and hand lay-up techniques at its Clearfield, Utah facility.

The F-35 Lightning II is a supersonic, multi-role, fifth generation stealth fighter. The three F-35 variants are derived from a common design and use the same sustainment infrastructure world-wide to replace at least 13 types of aircraft for 11 nations, reportedly making the Lightning II the most cost-effective fighter program in history.