CMC's (Ceramic Matrix Composites) provide durability and weight reduction in high temperature applications, such as engine components, but are costly to manufacture. Starfire proposes to develop RTM (Resin Transfer Molding) and CRTM (Compression Resin Transfer Molding), for the rapid manufacturing of near net shape CMC's incorporating fillers. Two approaches will be pursued to incorporate fillers, injecting filled slurry into a 2D or 3D preform and coating fabric with a compatible binder and fillers prior to laying up in the tool. We will develop techniques for both the HPZ pre-ceramic polymer currently used in the JSF flaps and seals, as well as our own SMP-10 pre-ceramic polymer. Starfire's SMP-10 pre-ceramic polymer advantages include the ability to add a catalyst to reduce out gassing during RTM curing, as well as its use as a compatible prepreggable binder for particle coating of 2-D reinforcing fabric. These variables will be tested concurrently with the HPZ resin system. The final deliverable will be F-100 flap(s) or seal(s) that will be engine tested at Pratt and Whitney. These same techniques are being considered for large volume commercial applications at Starfire including aircraft, automotive and motorcycle brakes.
