IM7/8552 Carbon/Epoxy Sine Wave Beam Pultrusion-Based Process Automation Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-016 Topic Title: IM7/8552 Carbon/Epoxy Sine Wave Beam Pultrusion-Based Process Automation Proposal No.: N081-016-0540 Firm: KaZaK Composites Incorporated 10F GIll Street Woburn, Massachusetts 01801-1721 Contact: Andrew Paddock Phone: (781) 932-5667 Web Site: kazakcomposites.com Abstract: Graphite/epoxy sine wave beams are used in several production aircraft, including wings of the F-22 Raptor. These lightweight structures replace traditional flat web I-beams with an undulating web surface that greatly increases buckling resistance, resulting in thinner, lighter, more durable structures. Because of their non-planar layout, traditional hand layup / autoclave cured fabrication of sine wave beams is extremely expensive. Approaches such as automated tape layup and resin transfer molding have reduced cost somewhat, but finished sine wave beams can still easily exceed $500 to $1,000 per pound. In the current era of cost-driven performance, disruptive manufacturing technology that significantly reduces cost is required. KaZaK proposes to develop and demonstrate a pultrusion-based technology for completely automating the production of sine wave beams using IM7/8552 prepreg. Previous work at KaZaK has suggested application of similar pultrusion technology to flat web I-beams reduces cost by a minimum of 50% compared to other fabrication approaches. KaZaK will interact with Sikorsky Aircraft to select an appropriate helicopter structure, ensuring that our evolving design and manufacturing methods, in combination with use of qualified prepreg, will speed the acceptance of this paradigm-breaking manufacturing technology by the aerospace industry. Benefits: Cost of hand layup / autoclave cure carbon / epoxy prepreg parts frequently exceeds $1,000 per pound for aerospace structures. Material costs are typically less than $100 per pound, with much of the remaining cost is associated with direct and indirect labor. KaZaK is proposing to develop and demonstrate a pultrusion-based manufacturing process that can reduce the cost of geometrically appropriate parts (including sine wave beams) by more than 50%. This level of cost savings redefines the current cost/performance model for aerospace prepreg structures, changing metal versus composite cost-driven trade decisions. Demonstration of the expected cost reductions compared to conventional prepreg processing methods during Phase I should allow major inroads to be made in many new aerospace applications. This SBIR technology could be applied to contribute to cost savings of similar magnitude for products made for the transportation and infrastructure markets. In addition, there may be major potential applicability to newly developing composite ship design and manufacture. Return