Automated SBCF MRB Spar (ASMS)(1001-175) Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-026 Topic Title: Automated SBCF MRB Spar (ASMS)(1001-175) Proposal No.: N081-026-0001 Firm: TRITON SYSTEMS, INC. 200 TURNPIKE ROAD Chelmsford, Massachusetts 01824 Contact: James Gorman Phone: (978) 250-4200 Web Site: www.tritonsys.com Abstract: Triton Systems Inc., in combination with HEXCEL, Ingersoll, and a helicopter or tiltrotor airframe prime contractor, proposes to develop a novel manufacturing technique combining the formability of stretch broken carbon fiber (SBCF) with automated fiber placement to dramatically reduce costs for high performance main rotor spars. The automated fiber placement promises to virtually eliminate the principal cost of making main rotor spars, and the SBCF characteristics promise to simplify the processing required to achieve high quality spars. During the Phase I Triton will develop a demonstration spar geometry in combination with the airframe prime, and fabricate the molding tooling required for several trials. Ingersoll will perform automated fiber placement on the demonstration mandrels, and ship the laid-up components to Triton. Triton will conduct molding and curing trials to develop the process to a finished quality level commensurate with main rotor spar requirements. During the Option Phase Triton will perform detailed NDE and destructive examination of the trial spar elements fabricated in the Phase I to identify the correlation between ultrasonic characterization and composite quality. Additional automated fiber placement panels will also be fabricated using SBCF in order to provide specimens for mechanical property testing, including tension, compression, and shear. Benefits: The combination of automated fiber/tape placement with the formability of stretch broken carbon fiber (SBCF) will provide a cost effective manufacturing approach for main rotor spars that demand the highest quality composite to sustain extremely high tension, bending and fatigue loadings. The automation of fiber placement will eliminate the largest element of rotor spar construction. The formability of SBCF in combination with an expanding mandrel and precision female tool will ensure precise dimensioning of the outer mold line of the spar. The high quality molding will facilitate all subsequent stages of the spar manufacturing. For the CH-53K helicopter alone, the production of main rotor blade spars is projected to be a Billion dollar business with peak rates of approximately $100 Million per year. The successful development of this spar molding technique will allow its penetration to the cost sensitive commercial market. Return