Arresting Cracks in Aluminum Ship Structure While at Sea Using Composite Patch Kits Navy SBIR FY2016.1 Sol No.: Navy SBIR FY2016.1 Topic No.: N161-069 Topic Title: Arresting Cracks in Aluminum Ship Structure While at Sea Using Composite Patch Kits Proposal No.: N161-069-0541 Firm: ZKxKZ 4 Constitution Road Lexington, Massachusetts 2421 Contact: Roger Crane Phone: (410) 562-2163 Abstract: ZKxKZ will develop a system for repairing cracks in sensitized aluminum ship structure optimized for use by minimally trained crew while underway. The proposed approach takes advantage of experience with in-port composite repairs of damage to CG-47s. Current repair technology, developed by proposal team members, is technically successful, but requires trained experts to successfully apply, and is therefore not useful for repairing damage discovered while at sea. The proposed system addresses current issues by providing ships with prepackaged composite patches, impregnated with resin, that use simplified methods for application of pressure, and cure at low temperature to avoid additional sensitization damage. In Phase I resin, fiber and user-friendly curing methods will be selected, a generically applicable laminate designed, and a kitted system that can be applied by ship's crew demonstrated. Phase I will include hardware tests showing a return of damaged aluminum structure to original strength and stiffness. Patch design and testing results will be supported by 3D FEA. A sailor-friendly repair catalog will be developed to guide at sea repairs by minimally trained crew. Commercialization path is patch kit, plus simple instructions, allowing crack growth and water intrusion to interior spaces to be halted without affecting a ship's mission. Benefits: The simplified composite repair kit proposed for development in this SBIR has potential applicability in many applications beyond the at-sea patching of damaged aluminum ship structure. Because the proposed approach will include standardized, prepackaged preforms, it will be easy to apply to any composite or metal vehicle, building or other military or civilian structure that requires an immediate structural repair that also returns the structure to a watertight condition. Proposal team members have already developed a similar kit for the repair of puncture damage to military ISO shelters and containers made with aluminum or composite sandwich panels. The kit will be equally applicable to repair of commercial vehicles and other lightweight structures. Return