Production-Optimized Composite Shafting with Novel Ballistically-Tolerant Laminate Architecture Navy SBIR FY2010.1 Sol No.: Navy SBIR FY2010.1 Topic No.: N101-097 Topic Title: Production-Optimized Composite Shafting with Novel Ballistically-Tolerant Laminate Architecture Proposal No.: N101-097-2113 Firm: KaZaK Composites Incorporated 10F GIll Street Woburn, Massachusetts 01801 Contact: Tim Mustone Phone: (781) 932-5667 Web Site: kazakcomposites.com Abstract: KaZaK Composites will leverage our currently active development program for new composite LCAC shafts, applying this evolving technology to development of similar composite CH-53K shafts. As CH-53K progresses through development, a novel drive shaft solution is desired that reduces weight and cost, and also improves ballistic durability compared to the legacy shaft. Composite material offers an attractive solution, but in some cases where traditional composite design and manufacturing methods such as braiding and RTM were used, weight savings from composite shafts were disappointing due to the additional material required to meet ballistic tolerance requirements. KaZaK proposes to work with world-class experts in composite materials and shaft design, along with a leading helicopter manufacturer, to demonstrate a novel laminate technology that has been shown to considerably increase strength and fatigue resistance compared to conventional layups. We will show that delamination resistance of our proposed laminate architecture will translate to enhanced ballistic performance, as has already been demonstrated for strength and fatigue. In Phase I KaZaK will develop a composite design optimized for our material approach (using IM7/8552), then produce and test samples demonstrating the efficacy of the new solution for mitigation of damage propagation, resulting in a lighter ballistically tolerant solution. Benefits: At the conclusion of a successful Phase II effort, the Navy will be in possession of a cost effective composite shaft solution that reduces weight while meeting all performance requirements, including ballistic damage. Once successfully tested, the KaZaK team will be in a position to commercialize this technology, first as a replacement for the current CH-53K baseline, and later for helicopter shafts. As part of our proposal preparation, KaZaK has already begun discussion of our shaft technology with two helicopter manufacturers. A likely progression of events following the completion of Phase II would include Navy Commercialization Pilot Program funding to complete the development testing required for certification of the shaft for CH-53K. The novel technologies embodied in the new shafts (a combination of design, material and manufacturing) will be useful to many other military and commercial applications, particularly when weight is important or shafts must operative in corrosive environments. The KaZaK team intends to actively pursue these markets and capture market share either through direct sales or licensing of technology to other manufactures. Some of the possible markets include but are not limited to aerospace, automobile, ship, and recreational vehicle shafting, racing components, and wind energy applications. Return