SBIR-STTR Award

Goodman Technologies(GT) with Navy DoD UARC University of Hawaii (UHM) proposes to demonstrate a prepreg consisting of bismaleimide (BMI), Toray T300 or Hexcel IM7 fabric, and our game changing and patent pending Orthogonal Nanoforest Technology (ONT), a mass-producible an aligned carbon nanotube (ACNT) material that we call Nanoforest III (NF III). Incorporation of NF III technology in the prepreg results in polymer matrix composites with superior orthogonal properties (GIC, strength, modulus, toughness). NF III can be incorporated into virtually all conventional composite manufacturing techniques. Cyctec CYCOM 5250-4 and Hexcel HexPly M65 are commercially available candidate systems for improvement. GT/UHM has already demonstrated a ceramic matrix composite (CMC) with ACNT system for the Air Force, mitigating risk for the Navy. GTs IM7/NF III/BMI prepreg will provide the requisite improvements in laminate orthogonal properties at high-temperature for Navy applications such as engine compressor and nozzle structures for GE-F414 engines, PMA-265 aircraft (F/A-18C/D Hornet, the F/A-18E/F Super Hornet, and the EA-18G Growler), the JPO F-35C Lightning II Pratt & Whitney F135 engine, and the yet to be definitized Next-Generation Air Dominance (NGAD) F/A-XX. GTs approach will be to fabricate, test, and show the orthogonal properties performance improvements obtained starting with IM7/BMI quasi-isotropic laminates [0/90/+45/-45]s with no CNT additions, then a) using additions of Nanoforest I grown on the reinforcement (NF 1 was first patented by UHM and is the growth of CNT orthogonal to plies, later called fuzzy fiber by some), and next using additions of b) NF I and Nanoforest II (NF 2 is an interlaminar nanotape with high alignment of the CNTs). We then plan to make coupons with our new NF III. The double cantilever beam (DCB) test, ASTM D5228, will be used to measure Mode I fracture energy GIC. The ASTM C1341 standard 4-point bending test and flexural equations will be used to determine strength, strain, modulus of the composite, and then to determine the laminate toughness via integration under the stress/strain curve. GT/UHM will use these standardized tests in a mini-matrix to elucidate orthogonal improvements obtained by aligned CNT additions, i.e., NF I, NF II, and our new patent pending NF III. This project is supported by 2 business divisions of Lockheed Martin, and composite suppliers HEXCEL and Solvay Composites who will contribute to Phase II planning with GT for NAVAIR. In Phase II GT plans to partner with these companies and perform a mega-matrix of properties testing (saltwater, fresh water, high-temperature, etc.) and make a prototype component.

Benefit:
Orthogonal Nanotube Technology (ONT) or Nanoforest III (NF III) is a 3D aligned carbon nanotube (ACNT) technology that is applicable to a great majority of polymer composite manufacturing techniques be it room temperature cure, autoclave cure, compression molding, resin transfer molding (RTM), open or closed mold vacuum assisted resin transfer molding (VARTM), reaction injection molding (RIM), structural reaction injection molding (SRIM), elastic reservoir molding (ERM), sheet molding compound (SMC), manual or automated and wet lay-up or prepreg role wrapping, co-cured sandwiched structures, pultrusion, manual or automated and wet lay-up or prepreg tape laying, in-situ (on-line consolidation) thermoplastic composites tape laying, filament winding by in-situ (on-line consolidation) thermoplastic composites tape laying, diaphragm forming, matched die forming, hydroforming, thermoforming, etc.; and for any geometry be it flat, curved, contoured, and multi-curvatures, and can be applied locally (i.e., around certain regions where the properties need to be improved locally) or globally (i.e., for the entire structure, where the properties need to be improved globally and everywhere in the structure). GTs IM7/NF III/BMI prepreg will provide the requisite improvements in laminate orthogonal properties at high-temperature for Navy applications such as engine compressor and nozzle structures for GE-F414 engines, PMA-265 aircraft (F/A-18C/D Hornet, the F/A-18E/F Super Hornet, and the EA-18G Growler), the JPO F-35C Lightning II Pratt & Whitney F135 engine, and the yet to be definitized Next-Generation Air Dominance (NGAD) F/A-XX. The technology is highly relevant for aeroshells, missile fairings and hypersonics air and space platforms, as well as underwater submersibles. There is potentially no composite system that would not benefit from NF III technology. This statement was vetted with a Private Investment Banker with deep understanding and connections to the marketplace, and assisting GT with the strategic pathway forward.

Keywords:
prepreg, prepreg, Nanocarpet, Nanotape, Nanoforest, orthogonal properties, jet engines, Aligned Carbon Nanotubes, polymer matrix composites

Goodman Technologies (GT) demonstrated 2 aligned carbon nanotube (ACNT) approaches (Nanoforest I, aka VACNT, and patent pending 3-Dimensional Nanoforest III, aka ONT) which provided double-digit percentage improvements in the fracture toughness of commercially available AFR-PE-4 and RM-1100 polyimide systems (Teijin/Renegade Materials), and in Carbon/Epoxy. GTs breakthrough ACNT enhancements of PMCs and CMCs will provide the requisite improvements in laminate orthogonal properties at the high-temperature required for engine compressor and nozzle structures: the GE-F414 engines used in PMA-265 (the Navys F/A-18 and EA-18G Program Office) which acquires, delivers and sustains the F/A-18C/D Hornet, the F/A-18E/F Super Hornet, and the EA-18G Growler aircraft, the Joint Program Office F-35C for the Navys F-35C Lightning II Pratt & Whitney F135 engine, and the as yet to be definitized Next-Generation Air Dominance (NGAD). The F110-GE-129 engine is used by the Air Force and foreign militaries for the Lockheed Martin F-16C/D Block aircraft, as well as the Boeing F-15QA Advanced Eagle. For Hypersonics key stakeholders are ONR Division 351 and Conventional Prompt Strike (CPS) at Strategic Systems Programs (SSP) with the primary customers being OPNA, COMUSSSTRATCOM, PEO (SUB), and PEO (Ships). The U.S. Army is a partner with the Navy for the Common Hypersonic Glide Body (C-HGB) VACNT and ONT presents an extraordinary opportunity for the F-35 Lightning II Program (PEO -F-35) and the three DoD Components which use this single-seat, single-engine, all-weather stealth multirole combat aircraft F-35A for the Air Force, F-35B for the Marine Corps, and F-35C for the Navy. The General Accounting Office (GAO) F-35 Reports 20-234T and 20-339 have stated DoD faces challenges in sustaining a growing fleet , and actions are needed to address manufacturing and modernization risks. The reports show that the summation of scrap, rework, and repair hours for all 435 of the F-35 variants increased in 2018-2019, >26,000 hours total in 2019. As of January 2021, there are over 610 aircraft built. Delamination failures are pervasive, as are achieving dimensional tolerances, a major problem for many aircraft programs. GT's Nanoforest composites increase toughness and strength, improve EMI/EMP shielding, reduce weight and radar cross section, and improve dimensional tolerances (tighter radii), and flame retardance. Improvements of 30-60% in fracture toughness can equate to proportionate reductions in scrap, rework and repair hours. Parametric analysis showed that when the F-35 fleet grows to >2400 air that nanoforest could save 33,000-73,625 hour/year Savings for Scrap, Rework, Repair. Using an average cost of $300/hour (no inflation) for Scrap, Rework, Repair, Multiply by 4-5 Decades Service, and the Savings range from $397M- $1107M, that gives Leverage of 397-1107X for a $1M SBIR investment.

Benefit:
Orthogonal Nanotube Technology (ONT) or Nanoforest III (NF III) is a 3D aligned carbon nanotube (ACNT) technology that is applicable to a great majority of polymer composite manufacturing techniques be it room temperature cure, autoclave cure, compression molding, resin transfer molding (RTM), open or closed mold vacuum assisted resin transfer molding (VARTM), reaction injection molding (RIM), structural reaction injection molding (SRIM), elastic reservoir molding (ERM), sheet molding compound (SMC), manual or automated and wet lay-up or prepreg role wrapping, co-cured sandwiched structures, pultrusion, manual or automated and wet lay-up or prepreg tape laying, in-situ (on-line consolidation) thermoplastic composites tape laying, filament winding by in-situ (on-line consolidation) thermoplastic composites tape laying, diaphragm forming, matched die forming, hydroforming, thermoforming, etc.; and for any geometry be it flat, curved, contoured, and multi-curvatures, and can be applied locally (i.e., around certain regions where the properties need to be improved locally) or globally (i.e., for the entire structure, where the properties need to be improved globally and everywhere in the structure). GTs aligned nanoforest enhancements will provide the requisite improvements in laminate orthogonal properties for numerous composite materials. The technology is also highly relevant for aeroshells, missile fairings and hypersonics air and space platforms, as well as underwater submersibles. There is potentially no composite system, including ceramic matrix composites, that would not benefit from our aligned naonoforest technologies. It is highly significant to note that ONT imparts multifunctional and multidirectional composite properties improvements (e.g., increased strength, toughness, thermal conductivity, reduced CTE, higher thermal diffusivity, higher electrical conductivity, EMI shielding and low observability, etc.).These statements wer vetted with a Private Investment Banker with deep understanding and connections to the marketplace, and assisting GT with the strategic pathway forward.

Keywords:
Nanotape, Aligned Carbon Nanotubes, prepreg, orthogonal properties, Nanocarpet, jet engines, polymer matrix composites, Nanoforest