TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-261 - CH53K Heavy Lift Helicopter, ACAT I

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: Develop and demonstrate a Thermoplastic Fiber Placement Head that is capable of managing, cutting and adding individual tows over complex contours.

DESCRIPTION: Structures such as the lower cabin and ramp skins of rotorcraft are candidates for the application of thermoplastics due to their inherent toughness. However the cost of producing structures with these materials remains a barrier to implementation. A process that combines both automation for placement of the material and simultaneous cure of the material offers promise in addressing the affordability of using thermoplastics for rotorcraft structure. Current thermoplastic fiber placement systems are limited to simple geometries with gentle contours. Furthermore, many of the systems lack the ability to manage individual tows of material which is required to fabricate more optimized complex parts with intricate ply details. This project will develop, integrate and demonstrate all of the technologies required to produce an in-situ thermoplastic fiber placement head that can be used to fabricate complex contour parts with intricate ply details. The system must be multi-tow (single tow/band placement systems are not of interest in this project) and be conformable. The ability of the system to produce laminate quality near that of autoclave consolidation processing must be verified through coupon testing. The resultant product must be capable of producing thermoplastic parts that can meet the weight, cost, and quality objectives of the acquisition programs.

PHASE I: Determine the feasibility of developing the desired fiber placement head concept. Determine the major technical challenges of the system shall be identified and risk mitigation plans produced accordingly. Preliminary drawings of the fiber placement head should be developed.

PHASE II: Mature the concept defined in Phase I. Design and construct a prototype fiber placement head. Fabricate representative complex contoured structural elements. Conduct coupon testing and first article cut up testing of the elements produced to assure laminate quality and integrity.

PHASE III: Transition the successfully developed technology to the fleet. The approaches, materials and processes developed should be readily applicable to commercial aerospace platforms where future platforms are seeking to utilize greater amounts of composite materials in a more affordable manner.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The approaches, materials and processes developed should be readily applicable to commercial aerospace platforms where future platforms are seeking to utilize greater amounts of composite materials in a more affordable manner.

REFERENCES:
1. Lamontia, M.A., M.B. Gruber, "Remaining Developments Required for Commercializing In situ Thermoplastic ATP"; SAMPE 2007, Baltimore MD, June 3-7, 2007. http://www.accudyne.com/SAMPE2007A.pdf.

2. Lamontia, M.A., M.B. Gruber, "Limitations on Mechanical Properties in Thermoplastic Laminates Fabricated by Two Processes: Automated Thermoplastic Tape Placement and Filament Winding"; 26th SAMPE Europe Conference, Paris France, April 5-7, 2005.

3. Chang, I.Y., Lees, J.K.; "Recent Development in Thermoplastic Composites: A Review of Matrix Systems and Processing Methods"; Journal of Thermoplastic Composite Materials, Vol. 1, No. 3, 277-296 (1988).

KEYWORDS: Thermoplastics; Fiber Placement; In-Situ; Placement Head; Automation; Complex Contour.

** TOPIC AUTHOR (TPOC) **

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