SBIR-STTR Award

Nevada Composites has developed Green-Aero(sm) toolinglightweight ceramic tooling that is stable under high pressure and long-duration cure cycles and can be washed out with water after cures to 370C (700F). Tools, whether single-sided or washout, have a composite-compatible CTE, provide tight tolerances, are reproducible, are stable to storage under ambient conditions, and are of affordable cost. All steps in the production process are environmentally benign. Tools, particularly washout mandrels, have been provided to several different military and commercial clients for use in processes including hand layup followed by autoclave cure, filament winding, and VARTM. Green-Aero(sm) tools offer both improved performance and cost improvements estimated at about 25% over sand mandrels. Nonetheless, for air platforms the current cost of complex tools is significantly above targeted values, lead time for tooling may be too long, and impact resistance and thermal shock behavior may not be at desired levels. The goal in Phase I is to advance the current TRL of 2 to 3 for reduced cost, etc., for air platform applications to 3, 4 or 5 for various options. At the end of Phase I we will also generate a plan for pursuing the most promising options in Phase II.

Benefit:
The technology and manufacturability improvements to Green-AeroSM tooling outlined in this Phase I proposal will raise the current TRL level of 2 to 3 to a TRL of 3, 4, or 5 for options we find to be worth pursuing in Phase II. If successful, the work will provide washout mandrels with highly desirable properties and at a extremely affordable cost. This will allow the Navy to save hundreds of thousands of dollars by replicating and replacing damaged components rather than going to the OEM to replace the entire assembly. The improvements will also be applicable to commercial applications and mandrel purchases.

Keywords:
improved performance, improved performance, Washout mandrel, Low Cost, Composite, coefficient of thermal expansion, Lightweight, Environmentally Friendly, Composite Compatible

Nevada Composites has developed Green-Aero(sm) toolinglightweight ceramic tooling that is stable under high pressure and long-duration cure cycles and can be washed out with water after cures to 370C (700F). Tools, whether single-sided or washout, have a composite-compatible CTE, provide tight tolerances, are reproducible, are stable to storage under ambient conditions, and are of affordable cost. All steps in the production process are environmentally benign. Tools, particularly washout mandrels, have been provided to several different military and commercial clients for use in processes including hand layup followed by autoclave cure, filament winding, and VARTM. Our Phase I work showed, however, that we could not yet meet the demands of rapid delivery time for the depots and that robustness and other properties still need improvement. The technology and manufacturability improvements to Green-AeroSM tooling outlined in this Phase I proposal will raise the current TRL level at the end of Phase I of 3 to 4 for depot use to a TRL of 5 after Phase II and 6 after the Phase II option. At the end of Phase II Option we will also generate a plan for transition to the depots as well as possible commercial transition in Phase III.

Benefit:
The technology and manufacturability improvements to Green-AeroSM tooling outlined in this Phase I proposal will raise the current TRL level at the end of Phase I of 3 to 4 for depot applications to a TRL of 5 after Phase II and 6 after the Phase II option. Our goal will be to develop our technology to meet repair depot demands. If successful, the work will provide washout mandrels with highly desirable properties at a cost and in a timeframe needed by the depots. This will allow the Navy to save hundreds of thousands of dollars by replicating and replacing damaged components rather than going to the OEM to replace the entire assembly. The improvements will also be applicable to commercial applications and can be expanded into production manufacturing.

Keywords:
Composite, Repair and replacements, Composite Compatible, Environmentally Friendly, Reduced Cost, Lightweight, Washout mandrel, Navy repair depot