CFOAM Durable Composite Tooling with High Performance Cement Coatings Navy SBIR FY2012.1 Sol No.: Navy SBIR FY2012.1 Topic No.: N121-033 Topic Title: CFOAM Durable Composite Tooling with High Performance Cement Coatings Proposal No.: N121-033-1315 Firm: Touchstone Research Laboratory, Ltd. The Millennium Centre 1142 Middle Creek Road Triadelphia, West Virginia 26059-1139 Contact: Harry Danford Phone: (304) 547-5800 Web Site: http://www.trl.com Abstract: Touchstone Research Laboratory, Ltd. proposes to develop a composite tooling technology based on its CFOAMr structural carbon foam as a core material with High Performance Cement (HPC) coatings. This approach will evaluate low CTE HPC coatings that have previously demonstrated a high degree of compatibility with CFOAM in high-temperature environments and will leverage Touchstone's experience in developing and commercializing CFOAM rapid prototype tools, which can be fabricated in 7 days. The HPC coatings to be evaluated are X-Pando, Aremco 551RN, and Graphibond 669. Touchstone will evaluate the performance of these HPC coatings at 0.125" and 0.25" thicknesses over CFOAM20 and CFOAM30 substrates (20 and 30 lbs per cubic-ft density). Test samples will be thermally cycled at 450�F (50 cycles) and evaluated for stress-cracking, hardness, flat-wise tensile strength, and vacuum integrity. All key raw materials to be tested are rated for 1,000�F continuous use applications. The potential for these tools to perform 450�F post-cures is clearly feasible. Benefits: The state-of-the art technology for aerospace and defense layup tools are Invar steel or CF composites with carbon fiberboard egg-crate structures. Two major constraints associated with Invar and CF composite tools are high cost and long tool procurement lead times. Touchstone's proposal to develop an innovative carbon composite tooling technology based on CFOAM structural carbon foam as a core structure with High Performance Ceramic (HPC) coatings has the potential to significantly reduce tooling costs and shorten procurement lead times. Additional high-value propositions for CFOAM HPC tooling include: rapid re-design capability, 450�F post-cure capability, lighter weight, reduced autoclave cycle times, and ease of repair. These additional benefits have the potential to significantly improve manufacturing performance and efficiencies at the Prime Contractor and Tier 1 supplier level by improving upon LEAN metrics such as takt time. The CFOAM/HPC composite tooling technology would be useful for both U.S. Dept. of Defense and commercial aerospace applications. Large prime contractors such as Boeing, Northrop Grumman, and Bell Helicopter would benefit greatly by having a CFOAM/HPC technology in their layup tool repertoire. Return