SBIR Phase I: High Rate Composite Tooling

这个小企业创新研究第一阶段项目将开发新的低成本，高性能的复合材料制造工具材料。在飞机上使用先进的纤维增强复合材料已经成为实现更高性能和更高燃油效率的必要条件。波音公司吗?波音787和空客？空客A350就是两架这样的飞机，它们是推动复合材料重量比超过50%的例子。其他交通工具也有类似的推动力。RTM工艺技术在降低成本和简化复合材料制造操作方面存在很大的机会。第一阶段的成果将通过降低成本和提高制造效率对复合材料行业产生重大影响。它将允许更广泛的制造基地来生产复合材料零件。通过在空中和陆基车辆上广泛使用节油复合材料，社会将看到效益。所开发的技术可以在项目结束后的5年内产生1000 - 2000万美元的年收入。这项工作还将促进先进陶瓷制造和大型航空航天制造商之间的合作。亚利桑那大学的本科生和当地高中生将有机会参与这个项目。这项研究的结果将在多学科会议和期刊上传播。该项目的智力优势在于开发低成本材料和制造工艺，使复合材料能够以高速率树脂传递模塑（RTM）生产。与基于高压灭菌器的工艺相比，RTM提供了几个关键优势。这包括：高内部和外部几何复杂性，更少的浪费，更低的挥发性排放，更高的生产率和卓越的表面光洁度。然而，高压的注射？高温树脂对模具提出了挑战。工具可能是使用RTM作为首选制造路线的限制因素。对于能够承受RTM条件并在固化周期后容易从复合材料中提取的新工具技术来说，存在很大的机会。一种可溶解的RTM材料将允许RTM应用的发展，并降低复合材料制造的成本。该项目将开发一种新的可溶粘合剂-骨料体系，可以承受所有RTM工艺条件。第一阶段的结果将展示一种低成本的RTM兼容工具系统，该系统可以高速成形并用于高速复合RTM循环。

This Small Business Innovation Research Phase I project will develop new low cost, high performance tooling materials for composite manufacturing. The use of advanced fiber reinforced composites in aircraft has become a necessity to achieve higher performance and greater fuel efficiencies. Boeing?s 787 and Airbus?s A350 are two such aircraft that exemplify the push to increase composite content above 50% by weight. There is a similar push in other transportation vehicles as well. A large opportunity exists for RTM process technology to reduce costs and streamline composite manufacturing operations. Phase I results will have a large impact on the composites industry through cost reduction and manufacturing efficiency gains. It will allow a broader manufacturing base to produce composite parts. Society will see benefits through the broader use of fuel efficient composites in air and land based vehicles. The technology developed can generate $10-$20M in annual revenue within 5 years of the program end. This effort will also foster collaboration between Advanced Ceramics Manufacturing and large aerospace manufacturers. Undergraduates at the University of Arizona and local high school students will have an opportunity to work on the project. Results of this research will be disseminated in multidisciplinary conferences and journals.The intellectual merit of this project is developing low cost materials and manufacturing processes that enable composite materials to be produced in high rate resin transfer molding (RTM). Compared to autoclave based processes, RTM offers several key advantages. This includes: high internal and external geometric complexity, less waste, lower volatile emissions, higher production rates, and excellent surface finish. However, the injection of high pressure ? high temperature resin presents a tooling challenge. Tooling can be a limiting factor for utilizing RTM as the preferred manufacturing route. A large opportunity exists for new tooling technology that can withstand RTM conditions and be easily extracted from the composite after the cure cycle. A soluble RTM capable material will allow RTM applications to grow and reduce the cost of composite manufacturing. The project will develop a new soluble binder-aggregate system that can withstand all RTM process conditions. The results of the Phase I will demonstrate a low cost RTM compatible tooling system that can be formed at high rate and used in high rate composite RTM cycles.