SBIR-STTR Award

This SBIR Phase I proposal will demonstrate the manufacture of a OOA composite using infrared radiation and compaction technology, an innovative resin film, and a resin film infusion process to produce aerospace quality thermoplastic composite. A low concentration of IR absorber is blended into a resin polymer and cast as a thin film. The resin film is interleaved with a carbon fabric reinforcement and the sandwich is irradiated using focused infrared radiation while applying pressure from compaction rollers in a lamination process. The heat and pressure infuse the resin film into the fabric to produce a carbon-reinforced thermoplastic composite. The Phase I program will build the infrared irradiation and compaction roller processing unit, fabricate composite laminate and test to demonstrate aerospace grade performance vs. the autoclave benchmark. The Phase I Option will optimize processing conditions, fabricate and fully characterize the mechanical performance of the composite laminate. A software program will compute setpoints for tape placement processing of resin infusion prepreg for scaleup in Phase II. The laminate performance data and tape placement processing conditions will be used to select, design and manufacture an aircraft sub-component part in the Phase II.

Benefit:
This resin infusion material and composite manufacturing process has a wide-ranging applicability in the transportation segment for both military and commercial use. Military and commercial aircraft design has moved to extensive use of composite materials for weight reduction at equivalent or greater strength and toughness. Likewise, the commercial business jet market continues to expand the use of composites in manufacturing. In addition, automobile manufacturers are incorporating composites in structural applications in future models to address fuel economy while maintaining safety. Therefore, this OOA technology addresses the need for increased manufacturing productivity and lower cost in the transportation manufacturing segment and can expect to rapidly penetrate the composite airframe market using US-developed technology. This project also benefits an undergraduate engineer who will participate in research and training on this program.

Keywords:
lamination, lamination, carbon fabric, interleave, film infusion, Compaction, Infrared Radiation, OOA, Thermoplastic composite

This SBIR Phase II proposal develops an innovative PTIR adhesive and process for bonding stud fasteners to composite surfaces in aircraft manufacturing and repair. The PTIR adhesive formulation has a low concentration of infrared emitter/absorber dispersed in a thermoset epoxy adhesive paste. The PTIR adhesive paste is applied to the base of a stud fastener and the stud is irradiated using a P-Wave near-infrared radiation unit to uniformly heat the fastener base, adhesive and glass/epoxy composite substrate and form a strong bond between the stud and the substrate. Phase II will design and build a P-Wave radiation system with waveguide and thermal feedback controller for use to irradiate and bond the stud while holding with a vacuum holding fixture. Thermal analysis and mechanical testing of candidate PTIR adhesive and substrate materials will define process conditions to rapidly cure the adhesive and with bonding strength that equivalent to the benchmark adhesive performance at a processing temperature below the substrate surface degradation limit. The PTIR adhesive formulation, P-Wave unit, holding fixture and PTIR OOA process will be scaled up to demonstrate high speed stud fastener bonding for aircraft manufacture and repair.

Benefit:
The PTIR adhesive system and P-Wave hardware deliver fast curing and high quality bonding needed to reduce repair time and operating cost and to maintain a high level of aircraft readiness for the Navy. The PTIR system can be applied to military and civilian aircraft markets that have moved to extensive use of composite materials for weight reduction at equivalent or greater strength and toughness. Likewise, the commercial business jet market continues to expand the use of composites in manufacturing and can use this fastener joining and repair process. This OOA technology addresses the need for increased manufacturing productivity, reproducibility and reliability in aircraft manufacture and repair and can expect to rapidly penetrate the composite airframe markets using this US-developed technology.

Keywords:
Composite, adhesive, Epoxy, thermoset, OOA, Infrared Radiation, fastener