Starfire® materials technology is playing a key role in the continued development of advanced ceramic materials.  The rate of acceptance into aerospace applications is accelerated by the cost, performance, and design advantages afforded by Starfire technology to the users and manufacturers of Ceramic Matrix Composites (CMCs).

The Fiber Preform, Fiber Coating, and Matrix are the three critical materials technologies necessary to produce an acceptable CMC. Whether you use ceramic or carbon fiber architectures, Starfire's unique fiber coatings and matrix polymers provide a low cost solution for critical design factors. The ability to apply Starfire coatings by conventional dip, or paint-on coating methods, and using well known resin transfer matrix forming methodologies ensures a low cost end product.

Ceramic polymer matrices have been successfully used in a wide variety of fabricated parts including heat exchangers; structural components for air frames and engine parts; and friction materials such as brakes and clutches. CMC materials are 60% lighter than steel and can withstand ultra-high temperatures that would melt metallic superalloys making them ideal for use on rocket nozzles, aircraft brakes, and aircraft exhaust systems. The following is a more in depth overview of the performance of Starfire silicon carbide brake materials systems currently under development:

• One-third the weight of comparable steel
• Up to 20% lighter than carbon/carbon (C/C)
• Excellent static friction
• Stable base friction (0.2) that can be tailored to exceed 0.35; both static and dynamic friction
• Friction rises smoothly at end of stop
• Significantly lower wear rates versus C/C
• Less dust than C/C
• Greater mechanical stability versus C/C
• Demonstrated 30 to 50% lower cost when compared to C/C
• Multiple rejected take off (RTO) capability on less structural mass as compared to C/C or metal
• Friction performance is unaffected by fluids or temperature
• Improved oxidation resistance
• Suitable for automobiles due to low wear and stable friction
• Compatible with broad range of complementary friction materials, such as loaded sponge iron pads, yielding smoother and quieter operation than steel brakes
• Eliminates overheating or fade associated with current heavy truck brakes under extreme highway conditions.

To learn more, please view the Aerospace Data Sheet
 
STARFIRE^®  SMP-10 in Space:
  
    Click picture to enlarge

The reflection in the astronaut's faceplate shows six coupons of heat shield material purposely gouged to simulate possible damage to the heat shield.   During this spacewalk (EVA 3 of STS-121) astronauts Piers Sellers and Mike Fossum used NOAX (non-oxide adhesive, experimental; a paste of SMP-10 and refractory powders) to repair the simulated damage.    Two of the test tiles were returned to the Johnson Space Center where they were arc-jet tested under reentry conditions to see if the patch job would hold up.   Both passed with flying colors.