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MATECH Receives Patent for Breakthrough High Temperature Ceramic Composites
 
Published Wednesday, November 13, 2019

(Westlake Village, CA, updated on November 12, 2019)—MATECH received a US Patent for its new process for fabricating Ceramic Matrix Composites (CMCs). CMCs are high temperature fiber reinforced composites with a ceramic matrix. Unlike monolithic ceramics, which are very brittle, CMCs provide toughness at high operating temperatures. MATECH’s new process enables even higher operating temperatures and durability compared with conventional CMCs in use today. This could greatly benefit the multi-billion dollar per year turbine engine manufacturing industry.

MATECH’s technology utilizes Field Assisted Sintering Technology (FAST) in a quicker, more cost-effective way to produce extremely low porosity and high modulus Silicon Carbide ceramic matrix composite components (such as turbine blades and vanes) that are able to withstand
extreme temperatures, up to 2700 degrees F, resulting in parts that have longer life, greater durability and need less active cooling. Compared with current Ni-based superalloys, these advanced airfoils would enable a roughly 25% increase in thrust to weight ratio and a 10% reduction in specific fuel consumption (SFC) for military and commercial aircraft, resulting in greater range and the ability to generate more power when necessary. These same improvements in efficiency can be exploited in long-range UAVs, unmanned turbine engine powered missiles, and commercial aviation.


Commercial and industrial applications in which FAST SiC CMCs could be used include:

     
  • Stationary gas turbine engines (electrical power generation)
  • Commercial and military aircraft engines
  • Friction materials (aircraft brakes, automotive brakes, etc.)
  • Ballistic Armor (for military and law enforcement personnel)


MATECH’s patent, entitled “FAST-Densified Ceramic Matrix Composite and Fabrication Method,” has been issued by the US Patent and Trademark Office (USPTO) on November 5, 2019 (US Patent Number 10,464,849). The technology has already generated interest from major turbine engine manufacturers and ballistic armor manufacturers. The development of this technology was supported by grants from the Office of Naval Research (ONR). MATECH was founded in 1989 by Dr. Edward J. A. Pope and is recognized as a world-class research and development laboratory in the areas of glass, ceramic, and high temperature ceramic composite material development. Dr. Pope is recognized as an international leader in materials science and engineering R&D. In 1995 he received the D.R. Ulrich Award for “outstanding work in the field of sol-gel science and technology,” (presented in Faro, Portugal) and the Woldemar A. Weyl International Glass Science Award (presented in Beijing, China). In April 2001, Dr. Pope received the prestigious Richard M. Fulrath Award of the American Ceramic Society (conferred jointly by The Ceramic Society of Japan).


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