TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-275, V-22 Program

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: Develop and demonstrate low-cost effective fabrication methods for a high performance large composite main rotor blade spar.

DESCRIPTION: Advances in composites have been beneficial to the United States Navy rotary wing community by offering improved fatigue performance and significant weight reductions with equivalent or improved strength capabilities as compared to metallic structure. However, composite aircraft components are expensive to fabricate and difficult to analyze. In particular, blade spars for large helicopters are thick walled, closed section parts with integral attachments that must withstand very high loads. Advanced automated, low cost, defect free fabrication methods are needed. Particularly for spars of increased size and various geometric requirements (taper, twist, etc), like the ones on the H-53 or the V-22 aircraft. Much of this cost is associated with tooling and the lack of automation. These high costs, and a perceived reduction in composite component durability and survivability, often prevent the transition of composite technology particularly for primary structure.

PHASE I: Research and develop innovative, advanced low-cost composite reinforcement fabrication methods of large high performance composite main rotor blade spars requiring increased torque and out-of-plane properties. Demonstrate feasibility and scalability of methods to manufacture representative components as well as the outline of a full-scale production manufacturing plan.

PHASE II: Using the blade geometry, strength and stiffness requirements gathered in Phase I; develop, demonstrate and validate proposed manufacturing methods. Include representative evaluations of building block mechanical testing and a manufacturing demonstration of a spar of representative size and structural configuration to demonstrate quality and scalability. Develop a manufacturing plan and cost benefit analyses with an Original Equipment Manufacturer (OEM), which support transition of the manufacturing process. Perform a risk reduction static and fatigue test with a mid-scale (aprox. 10ft) specimen that demonstrates all critical geometric qualities as well as appropriate strength, fatigue and dynamic requirements.

PHASE III: Demonstrate capability through production, fatigue test and static test of full-size prototype aircraft main rotor blade spar. Transition rotor blade spar to the fleet.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: This technology (composite manufacturing process, material forms, and designs) has wide-ranging applicability in both the public and private sector. As composite materials continue to displace metals in primary and secondary airframe structure, the focus is on affordability and improving durability in the service environment. This is true from both military and commercial operators. Therefore, this technology, if successful, can lead to greater penetration of the composite airframe market with US-developed technology.

REFERENCES:
1. Ross, A., "Will Stretch-broken Carbon Fiber Become The New Material Of Choice?" Composites World, January 2006: http://www.compositesworld.com/hpc/issues/2006/January/1143

2. Nelson, J., "Aluminum Frame Build Incorporates Carbon Fiber Tubes" Composites World, January 2006: http://compositesworld.com/hpc/issues/2006/January/1159/2

3. Mason, K., "Autoclave Quality Outside the Autoclave?" High-Performance Composites, March 2006: www.compositesworld.com

KEYWORDS: Aircraft; Rotary Wing; High Performance Composite; Structures; Component; Main Rotor Blade Spar

TPOC: (301)757-5531

** TOPIC AUTHOR (TPOC) **

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