R2R Fabrication of Millimeter Wave Dipole Chaff with High Radar Cross Section Navy SBIR FY2015.2 Sol No.: Navy SBIR FY2015.2 Topic No.: N152-082 Topic Title: R2R Fabrication of Millimeter Wave Dipole Chaff with High Radar Cross Section Proposal No.: N152-082-0113 Firm: Physical Sciences Inc. 20 New England Business Center Andover, Massachusetts 1810 Contact: John Lennhoff Phone: (978) 738-8156 Web Site: http://www.psicorp.com Abstract: Physical Sciences, Inc. (PSI) has developed a batch process to coat commercial carbon fibers (CF) with copper. The thickness of the copper coating and the diameter of the substrate fiber can be tuned to yield optimized chaff with high Radar Cross Section (RCS). Simulations and single fiber lab measurements indicate that the proposed copper coated CF (Cu/CF) provide 6.5X extinction compared to the current aluminum on glass (Al/SiO2) chaff at 35 GHz. PSI will convert this batch process to a roll to roll (R2R) pilot production system that will copper coat continuous CF tows. The CF tows will be laser cut to the target resonant length corresponding to 2 and 150 GHz frequencies. On the Phase I program, we will fabricate a small scale continuous process to demonstrate Cu/CF production and to provide chaff for characterization. Our partner, Prof. Charles Bruce at New Mexico State University, will provide chaff RF characterization. As part of a Phase I Option we will deliver laser cut Cu/CF packed in RR-129 cartridges to our partner, Esterline Defense Technologies, for dissemination testing. During the Phase II program, we will construct and optimize a pilot production system to produce 1 kilogram per hour of the Cu/CF. Benefits: Copper coated carbon fibers with high electrical conductivity may find very strong commercial use as a lightweight wire for low current applications. These conductive, high strength fibers may also be used as a reinforcement fiber for composite panels that provide electromagnetic (EM) shielding for electronics. These conductive fibers could be chopped and used as a conductive filler for polymer matrices. These conductive panels could be used as low cost EM shields. These fines conductive wires may be integrated, as single filaments, into a polymer coating to yield a transparent conductive surface. A broad range of commercial application exist for the fiber tow production described in this proposal. Return