N112-124 TITLE: 3 Dimensional (3D) Braiding of Non-Uniform Solid Cross-Sections

TECHNOLOGY AREAS: Air Platform

ACQUISITION PROGRAM: F-35, Joint Strike Fighter

OBJECTIVE: Develop an innovative technology for performing a 3-dimensional (3D) braid with a solid non-uniform cross-section.

DESCRIPTION: 3D braided composites are made by consolidating a braided fibrous preform with a resin. 3D braids are difficult to manufacture when the cross-section of the preform is solid (not hollow) but not uniform. Most braiding strategies use a fixed number of yarns or bobbins throughout the braiding process, making it difficult to introduce or subtract yarn during the process. The prevalent industry practice is to include inserts in the preform and overbraid over it. However, such techniques result in a weak interface that is prone to damage and failure during service. The goal of this project is to develop an innovative solution that will allow easy manufacture of braided preforms in which the cross-section can be varied in a controlled fashion.

PHASE I: Demonstrate the feasibility of braiding a 3D preform with a solid non-uniform cross-section in which the cross-section can be varied in a controlled fashion.

PHASE II: Based on the recommended approach in Phase I, fabricate a 3D braided component prototype using a production-scalable process.

PHASE III: Transition the approach to platforms that will benefit from the developed 3D braided composite technology.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Braided structures are widely used in aerospace, automotive, and biomedical applications. Examples of 3D braided composites include mechanical linkages and composite fasteners.

REFERENCES:
1. Chou, T.-W. & Ko, F. K. (1989). Textile structural composites. Amsterdam, The Netherlands: Elseveier. Retrieved from http://www.amazon.com/Textile-Structural-Composites-Composite-Materials/dp/0444429921

2. Campbell, F. C., Jr. (2003). Manufacturing process for advanced composites. Oxford, U.K.: Elsevier. Retrieved from http://www.elsevier.com/wps/find/bookdescription.cws_home/680863/description#description

KEYWORDS: textile composite; composites; braiding; non-uniform cross-section; fasteners; connecting rods

** TOPIC AUTHOR (TPOC) **

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