N112-100 TITLE: Laser Removal of Composite Coatings and Damaged Areas on Aircraft

TECHNOLOGY AREAS: Air Platform, Materials/Processes, Sensors, Electronics

ACQUISITION PROGRAM: PMA-275, V-22 Osprey

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports):  This topic is "ITAR Restricted."  The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data.  Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Develop a laser-based method to safely and quickly remove material on the surface of composites without adversely affecting the structure.

DESCRIPTION: Modern military aircraft use composites for at least a third of their structures, and the V-22 in particular contains a number of advanced composite structures. As the aircraft age and are exposed to hostile environments, these composite (i.e., multilayer) coatings need to be repaired and replaced. The current procedure for removing composite coatings on aircraft such as the V-22 uses sandblasting or chemical solvents. The limitations of physical sandblasting include a lack of sensitivity (i.e., inability to remove layer by layer), remnants of foreign debris, and most importantly, the potential to damage the underlying composite material. Chemical solvents have the aforementioned limitations and can also be carcinogenic and require costly storage and disposal.

A novel approach to improved coating removal technology is needed that can also be used to precisely remove damaged material prior to repair. Compact laser technology has been used in other applications and industries to provide quick, economical, efficient, and environmentally friendly solutions. A need exists to apply this laser technology to the task of precisely removing the existing outer layers of composite coatings and damaged material in an economically, environmentally friendly way without affecting the composite material or structure. In addition to laser expertise, knowledge of V-22 coatings and composites should be demonstrated. Successful candidates will also propose a suitable vapor collection method and end-point detection method to accompany the laser-based technique.

PHASE I: Demonstrate the feasibility of using compact laser technology to remove composite coatings and materials from aircraft without affecting the underlying composite material. The study should also demonstrate the feasibility of a suitable vapor collection and sensor for end-point detection.

PHASE II: Optimize laser and process parameters and deliver a prototype system (laser, vapor collection, sensor) for NAVAIR V-22 program evaluation. System stability should be closely examined quantitatively and reported. Extensive coupon testing should be performed for controlled removal and for validating the preservation of underlying composite material.

PHASE III: Perform extensive testing and evaluation as well as final system optimization, manufacturing, and commercialization. A sound business case for technology transition and commercialization should also be prepared, identifying key members of the DoD supply chain.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Both military and commercial aviation are using composite materials to a greater extent. In some cases, composites represent a majority of the material that is used on board aircraft. Having a quick, economical, environmentally friendly way of removing surface material without affecting composite material properties is advantageous to life cycle cost and reduced man-hours for both military and commercial organizations.

REFERENCES:
1. Vadillo, J. M., & Laserna, J. J. (2004). Laser-induced plasma spectrometry: Truly a surface analytical tool. Spectrochemica Acta Part B: Atomic Spectroscopy, 59, 147-161.

2. Hildenhagen, J., & Dickmann, K. (2003). Low-cost sensor system for online monitoring during laser cleaning. Journal of Cultural Heritage, 4(Suppl. 1), 343-346.

3. Whitley, J. Q., Kusy, R. P., Mayhew, M. J., & Buckthal, J. E. (1987). Surface roughness of stainless steel and electroformed nickel standards using a HeNe laser. Optics and Laser Technology, 19, 189-196.

KEYWORDS: laser removal; coatings removal technology; damaged composite surfaces; stripping of material; safe disposition of vapor-removed material; laser technologies for coating removal

** TOPIC AUTHOR (TPOC) **

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