Resin Infusible Carbon Fiber Unidirectional Broadgoods for Fatigue Dominated Applications
Navy SBIR FY2015.1


Sol No.: Navy SBIR FY2015.1
Topic No.: N151-072
Topic Title: Resin Infusible Carbon Fiber Unidirectional Broadgoods for Fatigue Dominated Applications
Proposal No.: N151-072-0250
Firm: Composites Automation LLC
9 Adelaide Court
Newark, Delaware 19702
Contact: Roger Crane
Phone: (410) 562-2163
Abstract: The development of a low-cost permeable unidirectional carbon fabric material without fiber undulation is needed in order to provide full property translation that is comparable to unidirectional prepreg. In this Phase I effort, Composites Automation LLC proposes to fabricate unidirectional carbon broadgood using thermoplastic binder with high enough permeability of the fabric to allow infusion processing. Particle loading will be minimum, but sufficient to bind the spread tows together and provide toughening and improved mechanical properties of the part after cure. The fabric microstructure can be controlled using the proposed process, has no fiber crimp and does not rely on local stitches to hold the fibers in place. Process throughput can be significant for lower particle fraction systems and is anticipated to be faster than any industrial NCF machine and be an ideal process to reduce cost.
Benefits: The SBIR will develop a low-cost manufacturing method for binder-based carbon non-crimp fabrics that provides adequate drapability and is scalable to large volumes needed for Navy and commercial applications. The eventual goal is to use standard commercial hardware and materials to produce the broadgood at low cost and risk while improving the fatigue behavior of the composite after VARTM processing. The material will be a higher performance replacement of existing NCF fabrics without impact on the processing approach. Target markets include various marine and wind blade applications.

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