TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-275 - V-22 Program

OBJECTIVE: Develop and demonstrate design and manufacturing methods applicable to large integrated composite structures using the latest generation of out of autoclave (OOA) processable composite prepregs and resin film infusion technology.

DESCRIPTION: Lightweight composite materials have been widely used in the production of military and other aircraft structures since the 1970�s and have displaced metals in large parts of the airframes of manned aircraft such as the F22, F35 and F18. In the case of unmanned aircraft, many of these have been designed almost exclusively from composites from the outset. Unfortunately, the use of advanced materials has resulted in neither structurally efficient designs nor in cost effective aircraft. The F35 is both less structurally efficient and more costly in dollars per pound than older aircraft such as the F15. As indicated in a recent DoD sponsored report on Reducing DoD Fossil-Fuel Dependence (JSR-06-135), significant attention was focused on lightweighting of manned and unmanned ground and air vehicles through advanced materials, such as composite structures. Both DoD and air and ground vehicle contractors are now paying attention to reducing costly fuel demand by employing new designs using composite materials that are being used by private industry.

A key enabling technology is the recent development of new OOA processable materials, which offer the same structural performance as conventional autoclave cured materials and can be readily implemented in a production environment, unlike the older generation OOA materials. These new materials should be supported by extensive material property databases.

PHASE I: Investigate low cost composite parts processing and fabrication characteristics including complementary tooling. Define development of additional property data and scalability up to the component and subcomponent level including fatigue data. Provide a plan for parts qualification for military aircraft through a building block approach.

PHASE II: Using results from Phase I, identify and select realistic rotorcraft airframe designs that can benefit from OOA manufacturing processes. Compile realistic requirements such as geometry, tolerances, loads, environment, damage tolerance, life-cycle costs, etc based on actual Navy rotorcraft airframe designs. Using the latest generation of out-of-autoclave processable composite material systems, develop manufacturing methods and tooling concepts for airframe designs and demonstrate feasibility and scalability of representative components in a laboratory environment.

PHASE III: Using a building block approach, develop, demonstrate and test a realistic, full-scale structure using an OOA manufactured design that meets structural integrity, weight, damage tolerance, and other requirements. Identify nonrecurring and recurring costs as a part of a comprehensive Technology Insertion Plan. Develop production quality, low-cost, low-maintenance airframe designs for military and commercial aircraft programs.

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. Player, J., Roylance, M., et al, "UTL CONSOLIDATION AND OUT-OF-AUTOCLAVE CURING OF THICK COMPOSITE STRUCTURES" Department of Materials Science and Engineering, Massachusetts Institute of Technology, Cambridge, MA http://web.mit.edu/roylance/www/sampe00.pdf

2. Byrne, C., "Non-Autoclave Materials for Large Composite Structures" Science Research Lab, Somerville, MA November 2000 http://www.stormingmedia.us/89/8974/A897483.html

3. Tatum, S. "LOCKHEED MARTIN DEMONSTRATES LOW-COST METHOD FOR MANUFACTURING LARGE, COMPLEX COMPOSITE STRUCTURES IN ADVANCED FLEET BALLISTIC MISSILE PROJECT" Press Release, Lockheed Martin, March 2001 http://www.lockheedmartin.com/wms/findPage.do?dsp=fec&ci=12144&rsbci=0&fti=0&ti=0&sc=400

4. "GKN Aerospace Develops Manufacturing Processes for Complex Composite Structures" Posted on The A to Z of Materials, July 2006 http://www.azom.com/details.asp?newsID=6054

KEYWORDS: Aircraft; High Performance Composite; Structures; Out-Of-Autoclave

TPOC: (301)757-5531
2nd TPOC: (301)342-9343

** TOPIC AUTHOR (TPOC) **

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