SBIR-STTR Award

Our Navy has two critical goals for this project (1) reduction in supply chain risk and (2) need to open additional sources of fiber for the Navys future needs. Advanced Ceramic Fibers (ACF) will achieve these two goals by setting up a domestic supply chain for manufacture of fiber based yarn(s) made from different discontinuous fiber types including nanofilaments and micron diameter fibers. ACF is known as a unique manufacturing source for advanced ultra-high temperature (UHT) fibers with some fiber types at TRL6. N231-072 supports Hypersonics and Space Technology with the objective to develop a manufacturing process in which for example short discontinuous silicon carbide (SiC) fibers can be formed into a yarn capable of integration into traditional weaving or braiding systems for the production of high strength, high temperature ceramic matrix composites (CMCs) as part of thermal protection systems. ACFs technical and management experience span the range from novel fiber manufacturoing to incorporaton into CMCs for turbine engine, hypersonics and space applications. We will achieve the project and objectives goals by 1. We shall adapt commercial yarn twist spinning machine used in forming continuous twisted fiber yarn strands from discontinuous micron diameter filaments (mm lengths) and in Phase II set-up a second yarn spinning machine for nano-filaments (100-500 nm lengths). ACF uses commercially available yarns (micron to nano-meter in diameter) in short and continuous forms for several going Phase II (government) and Phase III (client) projects. 2. We shall apply our patented fiber and manufacturing process to produce high temperature continuous and short SiC layered carbon (SiC/C) fibers (TRL6) and in Phase II include other metal carbide (MC/C) fibers and nano-filament s fibers with utility above 30000C. Our patents cover fibers & manufacturing of unique fiber CMC forms (Quad-XE).

Benefit:


Benefits:
ACF uses commercially available yarns (micron to nano meter diameter) in short and continuous carbon forms for forming MC/C fibers. Yarn production is process scalable to kilogram/hour uses commercial carbon fibers. ACF Yarn manufacturing approach is flexible for various types of discontinuous fibers, including CNT carbon and nano SiC. ACF yarn manufacturing is process scalable to kilograms quantities using feeder machines for discontinuous short fibers and single strand nano-filaments. ACF goal is to provide fiber yarns to USA Clients product domination in their respective markets. Commercialization Applications: ACFs anticipated transition from Phase II to Phase III includes a pathway for the OEM end-users, as well as other commercial users, to acquire specific materials technology and prototype CMC hardware for organization-specific evaluations. Throughout Phase II, ACF will focus on the continued development of relationships with partnered OEMs, as well as 1st and 2nd tier suppliers to the OEMs as opportunities are identified. Other commercialization opportunities include: Turbine Engine: GE and Raytheon-RTX UTRC/P&W) enhanced long-term oxidation performance, related to damage caused by ingested foreign objects ( i.e., sand, dust, etc.) Hypersonic: LM-HWT, Boeing, Textron Systems (Weapons) improved short-term oxidative performance, with high impact resistance against raindrops or other airborne foreign objects Aero-Structures: LM-Aero and Northrup-Grumman minimized erosion on leading edges and control surfaces air platforms Space (NTP, Heat shield): LM-Space, NASA impact tolerance against space debris

Keywords:
Discontinuous Fibers, Discontinuous Fibers, Nano-Filament Yarn, SiC Converted Fibers, UHT Ceramic Yarn