Advanced Composite Mast (ACM) for UMM Navy SBIR FY2004.1 Sol No.: Navy SBIR FY2004.1 Topic No.: N04-035 Topic Title: Advanced Composite Mast (ACM) for UMM Proposal No.: N041-035-0 Firm: KaZaK Composites Incorporated 32 Cummings Park Woburn, Massachusetts 01801-2122 Contact: Jerome Fanucci Phone: (781) 932-5667 Web Site: kazakcomposites.com Abstract: The Advanced Composite Mast (ACM) comprises the Guide Trunk and Fairing Assembly of the Universal Modular Mast. These components comprise 80% of UMM weight and are excellent candidates for composite part replacement. By converting both parts from duplex stainless steel weldments to composite designs, 900 pounds or 20% of the total UMM system weight can be eliminated. Design concepts shall be developed and sized for applied loads and stiffness requirements. Trade studies of weight, cost and manufacturing methods shall be performed such that optimized designs for both components shall be selected and defined in detail. Reliable weight and cost estimates shall then be prepared. A key feature in both components are linear bearings riding in precision slide tracks to guide the double-acting telescoping elements of the UMM. The ability of a molded composite part to achieve necessary dimensional tolerances, surface finish and cycle life (wear) in UMM operations shall be demonstrated via representative test articles with internal molded slide tracks. By molding these features (versus machined in the stainless parts), considerable machining cost can be eliminated, enhancing ACM affordability. KCI shall apply its considerable expertise developing similar, related composite parts for defense and marine applications. Benefits: Successful completion of Phase I and II of the ACM development program will result in demonstration of a UMM design that saves considerable weight, is affordable, will not corrode in the marine environment and can provide improved acoustic damping. These benefits are directly applicable to other weight sensitive machinery used by submarines and surface naval vessels. In addition, there are a wide variety of commercial mechanical components that use precision sliding interfaces, from machine tools and tracks for material handling and inspection systems, to robots and hardware used in the manufacture of computer chips. The demonstrated ability to make lightweight, large and very stiff composite structures with integrally molded precision slide tracks, as demonstrated by this SBIR, will open up the possibility of significant future commercial application and opportunity. Return