SBIR-STTR Award

Ceramic matrix composites (CMCs) are increasingly being considered for a variety of hot structure applications, both military and commercial use. CMCs offer improvements in durability, higher temperature capability and reduced weight. Rapid, reliable, and cost effective parts marking technology is necessary for in-process tracking and parts flow optimization, but the process is complicated for CMCs, given the high temperature exposures they are subject to during processing and in service. Ex One proposes to use short pulse laser technologies for the installation of Item Unique Identification (IUID) features on CMC components. The goal of the program is to develop a technique which is rapid, low cost, automated, and allows for automated scanning. Both picosecond and femtosecond laser marking technologies will be evaluated. Ex One will conduct picosecond marking tests and will team with Raydiance, a femtosecond laser manufacturer, for marking tests using femtosecond lasers. Additional team members include Rolls-Royce for application specific information relative to CMC components and ATK as a manufacturer of CMC materials and components. The team will provide an analysis of the manufacturing and utilization of CMC materials, two regimes of short pulse laser technology, parts marking expertise and evaluation of material properties following the marking process.

Benefit:
The anticipated results of the Phase I effort will be to develop and demonstrate an ultra short pulse laser process for direct laser part marking of CMC high temperature, rotating and non-rotating parts without introducing material degradation or decreased part life. These demonstration marks and subsequent analyses will be carried out on a variety of CMC materials used within the aerospace industry.

Keywords:
ceramic matrix composites, ceramic matrix composites, parts marking, short pulse lasers

Ceramic matrix composites (CMCs) offer improvements in durability, higher temperature capability and reduced weight. Rapid, reliable, and cost effective parts marking technology is necessary for in-process tracking and parts flow optimization, but the process is complicated for CMCs, given the high temperature exposures they are subject to during processing and in-service. The overall objective of this Phase II effort is to develop and manufacture a prototype laser marking/mark interpretation system for installation at a manufacturer of CMCs and components. The effort is divided into a base and an option effort. During the base effort, the laser marking and automatic interpretation processes will be validated and elements such as minimum marking depth, post marking material properties, optimal laser characteristics, and accuracy and repeatability of the technology will be quantified. The option effort will culminate in the demonstration of the prototype laser marking system on the factory floor processing actual aerospace components following a full sequence of polymer infiltration and pyrolysis manufacturing steps to track parts in service through multiple high temperature exposures. Ex One is partnered with ATK, a supplier of aerospace and defense products who will provide sample materials, components and evaluation and Pratt & Whitney, Rolls-Royce and General Electric.

Benefit:
Anticipated benefits include the ability to precisely install laser markings in CMC materials in seconds with no apparent damage to the material for in-process and in-service parts tracking. Applications include components for rocket and jet engines, gas turbines for power plants, heat shields for space vehicles, aircraft brakes and heat treatment furnaces.

Keywords:
ceramic matrix composites, parts marking, short pulse lasers