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An innovative, low-cost, rapid-prototyping technology has been used to produce a

Rapid Prototyping of Continuous-Fiber-Reinforced Ceramic Matrix Composites. S mall Business T echnology TR ansfer. Advanced Ceramics Research, Inc. Tucson, AZ. An innovative, low-cost, rapid-prototyping technology has been used to produce a

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An innovative, low-cost, rapid-prototyping technology has been used to produce a

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  1. Rapid Prototyping of Continuous-Fiber-Reinforced Ceramic Matrix Composites Small Business Technology TRansfer Advanced Ceramics Research, Inc. Tucson, AZ An innovative, low-cost, rapid-prototyping technology has been used to produce a Novel composite material that will enable the fabrication of a new generation of low-cost propulsion components for NASA and DOD applications INNOVATION • ACCOMPLISHMENTS • A new, flexible, rapid, low-cost process has been developed for fabricating ceramic matrix composites (CMCs). Fabrication costs are reduced by more that an order of magnitude time reduced by approximately a factor of six for a square, thin plate of material • The continuous composite co-extrusion (C3) process has been demonstrated with first-generation carbon-fiber-reinforced zirconium carbide matrix composites (C/ZrC). • Rapid and economical, C3 offers drastic improvements over current state-of-the-art processes (e.g., chemical vapor infiltration and polymer impregnation and pyrolysis) used to fabricate ceramic matrix composites. • Reusable C/ZrC has the potential to withstand erosive environments at temperatures in excess of 2500ºF. • Program objectives include:development of the fiber interface coating; material properties generation; production and evaluation of prototype parts; production of full scale components to be delivered at the end of the program. COMMERCIALIZATION • Patent filed January 2001: MSFC-315497-1 • Teaming with several strong commercial partners for application of this technology to the aerospace and energy industries. • Will provide components for testing to commercial customers concurrently with the fabrication of NASA’s sub-scale and full scale parts. • Develop other material compositions and components with the highly flexible C3 process. Automated fiber placement machine laying up extruded ceramic-encased fiber tows from Advanced Ceramics Research • GOVERNMENT/SCIENCE APPLICATIONS • SBIR 2000 Phase 11 awarded for development of Polar Lay-up C/SiC blisk using the C3 process (NASA8-01016). • CMCs fabricated with the C3 process include:integrated ceramic injector and CMC thrusters bladed disks, ducts, cryogenic tanks nozzles, thermal protection hot structure, and steering and thrust control vanes. • C/ZrC has the potential to enable reusable radiation-cooled thrust chambers MSFC Contacts: Tom Knight; 256-544-5353 MSFC Tech. POC: Mike Effinger; 256-544-5637 ARC Contact: Dr. Ranji Vaidyanthan, 520-573-6300 1996 Phase I; NAS8-00084; 1999 Phase II, NAS8-00192 Marshall Space Flight Center Subtopic: 3.04, Lightweight Engine Components March 2001

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