Advanced ceramic composites and ceramic coatings can provide functionality for a wide range of applications. In many cases, advanced ceramics are used when traditional materials aren't able to withstand certain conditions or offer the level of protection required. Ceramic composites and coatings can be extremely strong, resistant to high temperatures, and highly durable; making them ideal candidates for use in numerous industrial settings where heavy wear and tear or caustic environments require advanced levels of protection. Whether you're looking for advanced radiation shielding, advanced friction reduction components or any other advanced ceramic application, advanced ceramic composites and ceramic coatings have the potential to save money and increase efficiency on an industrial scale.
CERAMIC COMPOSITES (CVI-PIP) and COATING (CVD)
C(f) or SiC(f) - C, SiC, HfC, ZrC, NbC, TaC, TiC, B4C, HfB2, Mo,Zr,Hf Ir, Nb, Re
Fabrication of CMC components via a low-cost, rapid CVI process based on a gas-pulsed, reverse thermal gradient CVI (GP-RTG CVI)
- Hypersonic propulsion, “zero erosion” nozzle liner
- Divert attitude propulsion (DACS) thrusters
- Ion optics C(ϝ)/C grids
- Long-life, fiber interface coatings
- Lightweight injectors for DACS
- Graded Cf- SiC/HfC CMCs for Liquid Rocket Nozzles
Low-Cost Approach to CMCs
Develop processing approaches to fabricate CMCs at significantly lower costs than by conventional means
- Large ∆T – directional matrix growth, Functionally Graded Matrices
- Higher T&P – higher matrix growth rate
- Colder surface – maintains open surface porosity
- Cycling P – maintains high matrix growth rates
- Reactant consumption reduced considerably
- Allows variable matrix architectures
- Reduced processing/component costs
- Six-fold reduction in time, ten-fold reduction in cost
Ceramic Composites
Ceramic composites are hybrid materials that combine ceramic with metal, ceramic with ceramic, ceramic with plastic, or ceramic with other ceramic materials. By combining different ceramic materials, these advanced composite materials often possess superior strength and properties that far exceed those of individual components. Developments in ceramic composite technology have made possible a wide range of new practical applications in the automotive, aerospace, electrical/electronic and medical industries. While still expensive to produce due to the complexity of their manufacture, ceramic composites are being used increasingly by manufacturers who require high-performing components for specific functions. These advances have helped open a whole world of possibilities for complex structures and more efficient design solutions.
Ceramic Matrix Composite
For those looking to transport more heat and stress with ceramic materials, ceramic matrix composites (CMC) are the ideal choice. CMCs are constructed of ceramic fibers held together by ceramic or metal binders. This combination of ceramic and metal creates a material that is strong enough to withstand extreme temperatures and pressure while also lightweight enough for easy use and transportation. This versatility has made ceramic matrix composites a popular choice among automotive engineers, aerospace fabricators and other industries that rely on performance from ceramic materials.
CMC Fabrication
CMC fabrication is an attractive option for many engineering projects since CMCs are often light, strong, and resistant to high temperatures. CMC fabrication is a complex procedure that utilizes advanced technologies such as CMC powders, "laser processing," advanced metrology equipment, and mathematical analysis to ensure the CMC takes on the desired properties. TA&T’s CMC fabrication methods also involve joining CMCs components with other materials and processes such as infiltrating CMC preforms into a metal matrix or laminating thin layers of CMCs together to create multi-layer composites. When you need to manufacture lightweight, reliable parts even in sharply featured shapes through reliable replications, choose CMC fabrication.
Carbon Composites
Carbon composites are materials composed of carbon molecules that have been arranged in a specific pattern to create a durable material. Often found in the construction and design of airplanes, boats, and other various industries, carbon composite materials differ from standard materials because they possess increased strength, durability, and greater chemical resistance. Carbon composites' unique properties account for their wide range of applications; they are used to not only reinforce existing structures but also create lighter weight objects with an improved strength-to-weight ratio. Carbon composites are becoming more prevalent due to their versatility and dependability in aerospace, sports equipment, medical tools and implants, automotive parts, and more. This amazing material continues to revolutionize our world with its plethora of uses, and TA&T makes it easy to take advantage of all of these possibilities in your business.
Ceramic Components
Ceramic components are an invaluable resource for a variety of markets, due to their high strength-to-weight ratio and superior electrical insulation. Ceramics offer strong impact and wear resistance, as well as excellent thermal shock resistance. From ceramic capacitors for radar systems to ceramic brakes for automobiles, TA&T’s ceramic components provide a robust solution for many everyday items and cutting-edge technologies alike. Furthermore, ceramic materials are recyclable, eliminating any negative environmental consequences from their production or processing. With ceramic’s versatility it is no wonder that its importance in industry continues to rise.
Functionally Graded Material (FGM)
| X |
p (g/cc) Monolith |
p (g/cc) Cf/X |
p (g/cc) Cf/C-X |
p (g/cc) Cf/SiC-X |
|---|---|---|---|---|
| C | 1.8 – 2.1 | ~1.95 | ~1.95 | - |
| SiC | 3.22 | 2.25 | 1.81 | - |
| Re | 20.53 | 10.04 | 3.37 | 3.85 |
| HfC | 13.31 | 6.79 | 2.72 | 3.17 |
Assume: 40 vol% fibers and 15% porosity
Lightweight, Long Life (Cooled) Thrust Cells
Objective:
- To establish multiple-use thrust cells for 3rd generation RLV applications
- Establish cooled composite designs for use with LH₂/LOₓ fuels
- Demonstrate firing of liquid H₂ cooled CMC design
Results:
- C(f)/C-HfC₉₀/SiC₁₀ was selected and tested
- Three nozzles were fabricated and tested – surviving for more than 250 seconds at 4700˚F
- At chamber pressures of 500psi, CMC showed gas permeability
- No throat erosion was observed following 250 seconds at 4700˚F
Lightweight, Long Life (Cooled) Thrust Cells
Objective:
- Demonstrate low-cost, rapid CVI process for the fabrication of C(r)/SiC DACS thrusters
- Demonstrate significant cost reduction over existing Noveltex DACS thrusters (THAAD)
- Establish TA&T as a low-cost, second-source supplier of CMC DACS thrusters
Results:
- Established a rapid CVI process based on GP-RTG CVI
- Densified C(r)/SiC thrusters to ~85% in less than 40 hours
- Developed fully automated process control system for majority of CMC processing
- Demonstrated directional matrix growth and optimized process for DACS thrusters
PVD Magnetron Sputtered Coatings
Magnetron sputtered coatings – multilayered:
- Residual stresses significantly influence the coating bulk properties
- Developing process control to determine residual stress, texture, surface roughness, etc. of coating during growth
Properties:
- Thermal EBCS for SiC CMCs up to 2850oF
- Wear resistance – B₄C/SiC, B₄C/W, etc.
- Solid Lubrication – MoS₂/Au-Pd
- Quasicrystalline/Nanocrystalline coatings
- CrN/Cr2N Corrosion Resistant
Ready to Take Advantage of TA&T’s Composites & Coatings?
Our ceramic composites & coatings can help take your product to the next level. Give superior quality needing to drastically alter your existing business model or expand your space. Contact our team of experts today for more information and to get started.
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