Goodrich Corporation

The B. F. Goodrich Company

Loral Vought Systems Corporation

John S Linck

James Warren Rudolph

Jean-Francois Le Costaouec

Paul Perea

Weiming Lu

Ying She

Zissis A Dardas

Brian St Rock

Katherine E Waugh

Modesto Martinez, Iii

Chris T Kirkpatrick

Vijay V Pujar

Steven A Poteet

John E Holowczak

Christopher T Kirkpatrick

Thomas P Filburn

Philip William Sheehan

Christopher Charles Koroly

Edward Lee Morris, Jr

David M Shuford

Roy E Booth

Kyle Rosenbrock

Lance McWilson

Lauren Rosler

Christopher L Everhart

Richard Jones

Hannes Pum

Thomas Perea

Gregory J Loughry

Philip Sheehan

Daniel Register

John Weaver

Modesto Martinez Iii

A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a support structure moveable with respect to the female forming tool, and at least one bladder coupled to the support structure and configured to be received into the die recess. The support structure is configured to move the bladder(s) with respect to the female forming tool. The bladder(s) is/are configured to be inflated to apply a compressive force to compress and form a fibrous preform between the bladder(s) and the female forming tool.

Expandable male die bladder for match die shape-forming systems and methods

A method of making a carbonized preform for a carbon-carbon composite brake disk may comprise: stacking a plurality of textile fabric layers, each textile fabric layer in the plurality of textile fabric layers including oxidized polyacrylonitrile (PAN) fibers, each textile fabric layer in the plurality of textile fabric layers being more uniform than a typical fabric layer formed from cross-lapping; each fabric layer being thinner than a typical fabric layer from cross-lapping, needling the plurality of textile fabric layers to form a needled non-woven board; cutting a fibrous preform from the needled non-woven board; and carbonizing the fibrous preform. The resultant non-woven carbonized preform maintains a higher fiber volume and more consistent properties throughout than what would otherwise be achieved using a typical fabric layer from cross-lapping.

Carbon/carbon composites and methods of making carbon/carbon composites having increased fiber volume

A method of making carbon fiber material according to various embodiments of the present disclosure includes forming a polymer resin to have a polydispersity index (PDI) that is less than approximately 2.5. The method further includes spinning the polymer resin to create an acrylic fiber having an acrylic fiber length. The method further includes oxidizing the acrylic fiber while stretching the acrylic fiber to create an oxidized fiber that has an oxidized fiber length that is at least one of greater than or equal to approximately 100 percent (100%) of the acrylic fiber length. The method further includes carbonizing the oxidized fiber to create a carbon fiber.

Carbon fiber crystal orientation improvement by polymer modification, fiber stretching and oxidation for brake application

A single stage OPF-to-carbon preform shape forming method includes positioning an oxidized PAN fiber preform with a female forming tool, positioning a vacuum bag over the oxidized PAN fiber preform, and vacuum forming the oxidized PAN fiber preform into a shaped body. The vacuum formed shaped body (while still in the shape forming fixture) may be loaded into a carbonization furnace and carbonized. The vacuum bag may be burned away in the carbonization furnace during carbonization.

Carbonization shape forming of oxidized PAN fiber preform

A method of forming a composite component is provided. The method includes locating a fibrous preform, providing a slurry, mixing the slurry with sacrificial fibers, injecting the slurry into the fibrous preform, heating the fibrous preform, forming channels in the fibrous preform, and densifying the fibrous preform. The sacrificial fibers are suspended in the fibrous preform along an injection pathway such that heating the sacrificial fibers forms the channels along the injection pathway as the sacrificial fibers are burned away.

Sacrificial materials to improve chemical vapor infiltration of BC loaded preforms

A carbon/carbon brake disk is provided. The carbon/carbon brake disk may comprise a carbon fiber, wherein the carbon fiber is formed into a fibrous network, wherein the fibrous network comprises carbon deposited therein. The carbon fiber may undergo a FHT process, wherein micro-cracks are disposed in the carbon fiber. In various embodiments, the micro-cracks may be at least partially filled with un-heat-treated carbon via a final CVD process, wherein the final CVD process is performed at a temperature in the range of up to about 1,000&#xb0; C. (1,832&#xb0; F.) for a duration in the range from about 20 hours to about 100 hours. In various embodiments, the un-heat-treated carbon may be configured to prevent oxygen, moisture, and/or oxidation protection systems (OPS) chemicals from penetrating the carbon/carbon brake disk. In various embodiments, the final CVI/CVD process may be configured to increase the wear life of the carbon/carbon brake disk.

Systems and methods for producing a carbon composite material

A system is disclosed comprising a carbon/carbon brake disk comprising a carbon fiber having a crystal orientation (CO) between 80% and 100% and a coefficient of friction of more than 0.183 in response to a rejected takeoff condition.

High performance carbon fiber

A process for densifying an annular porous structure comprising flowing a reactant gas into an inner diameter (ID) volume and through an ID surface of the annular porous structure, flowing the reactant gas through an outer diameter (OD) surface of the annular porous structure and into an OD volume, flowing the reactant gas from the OD volume through the OD surface of the annular porous structure, and flowing the reactant gas through an ID surface of the annular porous structure and into the ID volume.

Systems for modifying pressure differential in a chemical vapor process

A method of making a carbon-carbon composite part may comprise fabricating a fibrous preform comprising a fiber volume ratio of 25% or greater, heat treating the fibrous preform at a first temperature, infiltrating the fibrous preform with a first ceramic suspension, densifying the fibrous preform by chemical vapor infiltration (CVI) to form a densified fibrous preform, and heat treating the densified fibrous preform at a second temperature of 1600&#xb0; C. or greater.

Carbon/carbon composites and methods of making carbon/carbon composites having increased fiber volume and ceramic compounds

The method may include forming fibers with a silicon-based sizing, forming a fibrous preform from the fibers, forming a silicon dioxide coating around the fibers, carbonizing the fibrous preform, and densifying the fibrous preform. In various embodiments, forming the fibers with the silicon-based sizing includes utilizing a mass of the silicon-based sizing that is at least 1.0% of a mass of the fibers.

Oxidation protection for carbon-carbon composites

A preform manufacturing apparatus comprising a supply of fiber strip, a moveable positive fiber strip delivery mechanism coupled between a desired lay down location and the supply of fiber strip to positively deliver and orient the supply of fiber strip to the desired lay down location, and an electronic unwinder coupled to the supply of fiber strip is described herein. The electronic unwinder is configured to interact with the moveable positive fiber strip delivery mechanism.

System and method for manufacturing net shape preform from textile strips

A loom system for making a fibrous preform may comprise a base, a bedplate coupled to the base, wherein the bedplate is configured to rotate about an axis of rotation, and an air entangling module coupled to the base. The air entangling module may comprise an air entangling head coupled to an outer support and an inner support, wherein the air entangling head is configured to apply a jet of air toward the bedplate at an entangling zone. The air entangling head may have freedom of motion along the outer support and the inner support, and may be configured to rest on top of a fibrous layer.

Systems and methods for air entanglement

Methods for modifying pressure differential in a chemical vapor process

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Peublo, CO, United States of America

John S Linck