Reduced Cost, Repeatable, Improved Property Washout Tooling for Composite Fabrication

Nevada Composites has developed Green-Aero(sm) toolinglightweight ceramic tooling that is stable under high pressure and long-duration cure cycles and can be washed out with water after cures to 370C (700F). Tools, whether single-sided or washout, have a composite-compatible CTE, provide tight tolerances, are reproducible, are stable to storage under ambient conditions, and are of affordable cost. All steps in the production process are environmentally benign. Tools, particularly washout mandrels, have been provided to several different military and commercial clients for use in processes including hand layup followed by autoclave cure, filament winding, and VARTM.Our Phase I work showed, however, that we could not yet meet the demands of rapid delivery time for the depots and that robustness and other properties still need improvement. The technology and manufacturability improvements to Green-AeroSM tooling outlined in this Phase I proposal will raise the current TRL level at the end of Phase I of 3 to 4 for depot use to a TRL of 5 after Phase II and 6 after the Phase II option. At the end of Phase II Option we will also generate a plan for transition to the depots as well as possible commercial transition in Phase III.