Improved Resin Injection Repairs for Polymer Composite Materials Navy SBIR FY2012.1 Sol No.: Navy SBIR FY2012.1 Topic No.: N121-020 Topic Title: Improved Resin Injection Repairs for Polymer Composite Materials Proposal No.: N121-020-0422 Firm: Applied Poleramic, Inc. 6166 Egret Court Benicia, California 94510-1269 Contact: Brian Hayes Phone: (616) 458-1447 Web Site: www.appliedpoleramic.com Abstract: Composite structures are often damaged during manufacturing or in service. Depending on the level of damage, the part will require repair or replacement to make operable and safe for flight. While there are many different types of repair methods, resin injection offers a less intrusive method of repair and does not require near the post-processing of other methods. However, this method of repair has usually only been utilized for cosmetic purposes and has not allowed the complete restoration of the structural performance of the part. This is due to many reasons including the repair resin rheology and wetting, compatibility and reactivity of the repair resin to the substrate, and mechanical properties. Accordingly, a resin having the necessary viscosity, wetting, and adhesion characteristics along with aircraft matrix mechanical properties would make a unique resin injection repair material that could enable restoration of the performance of the damaged part to its original capability. This would initially find significant use in reducing costs associated with manufacturing related flaws such as those occurring in the development program of the CH-53K heavy lift helicopter as well as other Navy aircraft. Benefits: The injection repair resin developed in this research will enable cost effective repair of delaminated areas and other damages in composite parts. This new technology will enable structural repair of composite parts that have traditionally been repaired using other more invasive repair methods such as scarfed repair. The new injection repair resin will be able to be utilized for all types of aerospace epoxy matrix composites with a range of reinforcements. The initial use of the injection repair resin is anticipated for repair of manufacturing related flaws in composite parts developed by Spirit Aerosystems for the CH-53K heavy lift helicopter program. This repair resin may also find use at the other composite part subcontractors to Sikorsky including Aurora Flight Sciences, ITT Integrated Structures, and GKN Aerospace. Other aircraft companies, Boeing, Lockheed Martin, and Northrop Grumman and aircraft composite parts suppliers may also benefit from this repair technology. Air Force aircraft platforms may also benefit from using injection repair for repairing manufacturing and in service related damage to composite parts. There is a private sector market where injection repair could be utilized including composite tooling, and composite parts on trains, boats, automobiles, space vehicles, and wind blades. Return