The new FAST CAR2 technology, developed by the Johns Hopkins University Applied Physics Laboratory, drastically reduces the production time for carbon-carbon composites. While traditional manufacturing takes weeks or months, the full cycle is now reduced to a few days, with the key densification stage taking only a few minutes.
Carbon-carbon composites are characterized by low mass, high strength, and the ability to withstand extreme temperatures. They are used in the heat shields of hypersonic vehicles and returning spacecraft, rocket engine nozzles, rocket nose cones, and aircraft brakes.
The FAST CAR2 method utilizes field-assisted sintering technology. A carbon-containing material is placed directly into a fibrous blank, followed by the same-time application of high pressure and rapid electrical heating. This allows the dense structure to be formed in minutes.
The developers believe this technology will increase the output of heat-resistant composites and lower their cost. The team is currently collaborating with organizations that have larger presses to scale the technology from laboratory samples to full-size parts.
