Application of DFEM in Sintering Distortion Analysis of Oxide–Oxide Ceramic Matrix Composite: Digital Twin

ABSTRACT It is time‐consuming and expensive to calibrate the sintering behavior of a ceramic part because of the elevated temperature environment. A Densification‐Based Finite Element Method (DFEM) was developed for calculating the sintering distortion of ceramic parts without detailed knowledge of their constitutive law (such as viscosities and sintering potential). Given this advantage, this study presents the application of a DFEM for predicting and mitigating sintering distortion in a Full‐Scale Heat Shield (FSHS) made of oxide–oxide ceramic matrix composites (Ox‐Ox CMCs). DFEM was used to develop a digital twin that accurately identified geometric regions prone to distortion and quantified deviations between experimental measurements and finite element predictions. Suppression strategies were evaluated by applying boundary conditions, demonstrating a significant reduction in distortion in targeted regions. The findings highlight DFEM as an approximate yet computationally efficient approach, capable of eliminating the need for extensive material characterization, such as fiber orientations, ply numbers, matrix compositions, and sintering profiles. Instead, this information is inherently reflected in the measured sintering deformation, including distortion. This study establishes a foundation for further research into addressing distortion causes and optimizing sintering processes for improved manufacturability in aerospace applications.