SBIR-STTR Award

Robust 2700 F MC/C Fiber Reinforced Matrices for Turbine Engines
Award last edited on: 10/29/2018

Sponsored Program
SBIR
Awarding Agency
DOD : Navy
Total Award Amount
$1,825,101
Award Phase
2
Solicitation Topic Code
N141-074
Principal Investigator
John E Garnier

Company Information

Advanced Ceramic Fibers LLC

2300 North Yellowstone Highway Suite 210
Idaho Falls, ID 83401
   (208) 522-6008
   kkoller@acfibers.com
   www.acfibers.com
Location: Single
Congr. District: 02
County: Bonneville

Phase I

Contract Number: N00014-14-P-1130
Start Date: 5/5/2014    Completed: 3/5/2015
Phase I year
2014
Phase I Amount
$149,950
Advanced Ceramic Fibers, LLC has developed a transformational enabling fiber technology for use in UHT turbine engines - alpha silicon carbide/carbon based fibers - with capability above Navys goal of 2700 F. Our turbine engine OEM and aerospace team members are excited about the MC/C fibers for use in more robust/durable CMCs with higher temperature capability for turbine engines (TE). ACFs has experience in EBCs and trap sealants for TE static and rotating components to 4000 F. ACFs in-house technical team is highly experienced in development of fibers and CMCs for turbine engines and highly qualified to develop the physics and thermo-chemical-based models for MC/C fiber reinforced UHT ceramic composites with improved environmental robustness to mitigate effects of moisture-induced volatilization or corrosive deposits, or matrix cracking in high temperature gas turbine hot section components. Physics modeling will include both steady and kinetic models using Density Functional Theory (initial stages of chemical reactions) with non-first principles MD simulations for longer exposure times. IN Phase I, we will fabricate MC/C test coupons for use in CMC matrices. These materials will lead the way in Phase II to new TE designs.

Benefit:
COMMERCIALIZATION STRATEGY ACFs innovative high performance, low cost fibers is a disruptive technology (patents pending) that is beginning to impact a broad spectrum of Commercial and Defense needs using high temperature high performance fibers. Advanced Ceramic Fiber Solutions (ACF-S) was formed in 2013 to develop specific products, along with our strategic alliance partners, in our five major market segment targets: infrastructure, transportation, energy, aerospace, and defense. As co-inventor of the patent-pending alpha silicon carbide/carbon fiber (a-SiC/C) Direct Conversion Process 0x9D , Dr. Garnier has assembled a highly experienced team of professionals with extensive scientific, engineering, legal, production, and senior level management personnel developing the new business startup. Advanced Ceramic Fibers technical team has a breadth of experience in developing a materials technology and rapidly 0x9D transitioning it through the product development stage into the commercial markets. We are confident in our ability to make the family of emerging MC/C fibers the enabling technology for robust and durable CMCs armor supporting Navys use of man-rated and smaller turbine engines for their multiple specialty missions. We plan to take the next necessary development steps, perform more rigorous sub-component tests for longer duration, and work to scale-up the fabrication process in order to deliver profitable products to the marketplace as shown in at our web site: www.acfibers.com We establish these new product lines by spinning off our own manufacturing subsidiaries (ACF-S) or by establishing licensing and royalty agreements with highly motivated 0x9D major manufacturers. ACF, LLC has recently established a second commercialization entity Advanced Ceramic Fibers-Solutions, LLC for the purpose of rapidly setting up additional MC/C fiber related fabrication facilities in the US. Advanced Ceramic Fibers is committed to converting its SBIR research Programs into both commercial products and commercial R&D services, for both the private sector and Government markets, through Phase II Programs, and Phase III programs with industrial partners. Our current management strategy to achieve commercialization success is given in more detail in the separate appended Company Commercialization Report 0x9D as ACF has not received any prior SBIR award. One of our prime strategies is to involve the end user early in the development process. We are working with major defense OEMs for use of our MC/C fibers into various metals and metal vehicle and armor systems. We will foster those and other relationships during the program in order to insure that the technology development path remains directed at impacting CMCs for turbine engines in the most effective way possible. PHASE III DUAL-USE APPLICATIONS: We plan to Partner with interested USA turbine engine manufactures to embed ACFs MC/C fibers into CMCs in many turbine engine related market sectors. ACFs low-cost MC/C fibers opens up use of fiber reinforced CMCs into new markets for turbine engines i.e. transportation by hybrid truck driven by high efficiency CMC based TEs. Commercially, new CMC based TEs using ACFs MC/C fibers offers low-cost efficiency solutions with the benefits cited above thus enabling ACF to partner with a vehicle manufactures as well as turbine engine manufactures. We are engaging with OEMs of military trucks and vehicles and automobiles who have interest in low cost high performance fibers for a palette of end-use applications outside turbine engines as well. ACFs related business plan and projected growth for advanced CMC based turbine engines using MC/C fibers through 2030 is given in the technical proposal. See web site: www.acfibers.com for more information. Marketing data comes from a variety of published reports, such as Ceramic Bulletin, Journal of American Ceramic Society, American Society of Mechanical Engineers (ASME), US American Ceramic Association (USACA) and Directed Energy Society (web site: DES.org). IN 1980's ACFs PI, Dr. Garnier was involved in a multi-year DOE program matching small turbine engines with CMC heat exchangers to demonstrate 60+% efficient auxiliary turbine engine based power units for use in the Ford Taurus automobile. High cost of fiber ($6,000 pound) was a key-limiting factor preventing the demonstrator program from moving to Phase III. ACF MC/C fibers are low-cost. ACFs advanced low-cost MC/C fibers and related processing technologies are a core segment of our movement to Phase III plan for turbine engines and we will devote our full resources to successfully develop and transition technology to national defense and commercial applications.

Keywords:
silicon carbide, silicon carbide, trap sealants, High Temperature, Trade Study, Fibers, Ceramic Composites

Phase II

Contract Number: N00014-16-C-2020
Start Date: 2/5/2016    Completed: 5/7/2019
Phase II year
2016
Phase II Amount
$1,675,151
Advanced Ceramic Fibers, LLC (ACF) completed the Navy SBIR Phase I Base Program and clearly demonstrated the feasibility of our approach to create a truly robust composite for turbine engines that exceeds the known boundaries for ceramic composites and the Navy performance objectives for this Topic. Our engineered materials approach involved in-depth background experience in ceramic matrix composites (CMCs), modeling and selection of materials to combine ultra-high temperature (UHT) alpha silicon carbide/carbon (a-SiC/C) fibers with a proprietary interphase debond layer with a silicon carbide ceramic matrix. These composite materials opened up an entirely new world of stronger, more stable, lightweight, UHT design opportunities that were previously unknown and makes further development efforts truly compelling. The development of 2700 degree F capable fiber reinforced ceramic matrix composites (FRCMC),with enhanced material performance in salt and moisture environments, is critical to achieving higher military turbine engine performance utility.

Benefit:
The primary focus of this Phase II effort is to produce robust, fiber-reinforced ceramic matrix composites for components which can realize the Navy goal of 2700F turbine engines. Fortunately, this same fiber and FRCMC technology can be readily expanded to metal and/or polymer matrix composites with potential Navy applications including, but not limited to: hypersonic missiles, leading edges, naval vessel superstructures, advanced lightweight vehicle and personal armor technologies, aerospace and re-entry vehicle components subject to ultra-high temperatures, building components (including ballistic/blast resistant concrete), weaponry, and even efficient turbine auxiliary power generation. ACFs fibers and composites are foundational and affordable material constituents which present an entirely new palette of design possibilities that could revolutionize the tools 0x9D needed to support the Navy warfighter, whether at sea, in air or on land.

Keywords:
Composite, Fiber-reinforced Ceramic Matrix Composite, Low Cost, Ultra High Temperature, silicon carbide fiber, Alpha Silicon Carbide/Carbon Fiber, High Performance