Hybrid Carbon/Aramid Composite Drive Shaft with Captured Titanium End Fittings Navy SBIR FY2010.1 Sol No.: Navy SBIR FY2010.1 Topic No.: N101-097 Topic Title: Hybrid Carbon/Aramid Composite Drive Shaft with Captured Titanium End Fittings Proposal No.: N101-097-0615 Firm: Aurora Flight Sciences Corporation 9950 Wakeman Drive Manassas, Virginia 20110 Contact: Brandon Pollett Phone: (304) 848-5957 Web Site: www.aurora.aero Abstract: Aurora proposes to enhance the CH-53K helicopter drive shaft by reducing the weight and improving its ballistics survivability through the use of advanced composite materials. The new drive shaft will utilize carbon and aramid fibers, an advanced BMI resin system, and captured titanium end fittings in conjunction with existing metal components to reach these improved performance goals. A hybrid composite design also allows for material property tailoring to better meet the structural, dynamic, and environmental requirements imposed on the drive shaft. A composite drive shaft solution that is light weight, low cost, and provides operational performance after incurring ballistic damage would greatly benefit the overall value, performance, and survivability of military rotary wing assets. Benefits: Aurora envisions this SBIR Phase I program as a first step towards a series of efforts needed to engineer, fabricate, test, evaluate and qualify a composite drive shaft that would eventually transition into the CH-53K production program. The goal of this research effort would be to demonstrate the potential of Aurora's proposition and create an avenue to seek the support of the Sikorsky Aircraft Corporation and the PMA-261, CH-53K program office, towards a full qualification program. Further research work will be focused on developing a rate production processes, and developing project plans that eventually lead to product integration into the CH-53K airframe. These efforts will be in conjunction with research into other opportunities to market this ballistic drive shaft technology on other U.S. military platforms; fixed wing aircraft and ground vehicles. Current estimates of the CH-53K production run ranges between 150 to 300 aircraft. At a ROM price of $100K per drive shaft system this estimate constitutes a range of $15 Million to $30 Million in potential revenue to Aurora as a result of the CH-53K platform. Yet, the same technology can be deployed to other rotary wing platforms such as the UH-60Ms and the AH-64s. Both helicopter platforms are still in production with an estimated 741 AH-65s and 1500 UH-60s already in the DoD inventory. Without a doubt, considering the inventory for rotary wing platforms and the absolute need for survivable light weight components for such platforms, a successful outcome of this SBIR effort along with successfully executed development, testing and qualification programs would guarantee the transition of this technology to current Department of Defense rotorcraft production programs. Return