Resin Infusible Carbon Fiber Unidirectional Broadgoods for Fatigue Dominated Applications

Texas Research Institute Austin (TRI/Austin) is proposing to develop and demonstrate a fugitive stitch fiber solution to the issue of poor fatigue life in resin infused carbon unidirectional (stitchbond) fabrics. TRI/Austin will evaluate to candidate fugitive stitch materials, one currently commercially available and the other undergoing initial development in the proposed effort. The candidate stitch materials will be used to produce approximately 40 yards of quasi-isotropic fabric and this fabric will be consolidated into plates using the API SC-15 epoxy resin. The fabric and consolidated plates will be evaluated for physical and mechanical properties in the Phase I Base effort and the consolidated plates will be evaluated for fatigue life in the Phase I Option effort. Materials, both dry fiber and consolidated plates, will be provided to the Navy for independent evaluation. A Phase II Program Plan will be generated during the Phase I Base effort that will leverage the existing industry capacity to produce stitchbond fabrics. An overall review of the manufacturing process will be conducted in the Phase I Option effort to identify areas where changes in the process can lead to lower costs and higher performance composites.