Low Cost, Low Weight Composite Structure using Out-Of-Autoclave (OOA) Technology

This SBIR Phase II proposal develops an innovative PTIR adhesive and process for bonding stud fasteners to composite surfaces in aircraft manufacturing and repair. The PTIR adhesive formulation has a low concentration of infrared emitter/absorber dispersed in a thermoset epoxy adhesive paste. The PTIR adhesive paste is applied to the base of a stud fastener and the stud is irradiated using a P-Wave near-infrared radiation unit to uniformly heat the fastener base, adhesive and glass/epoxy composite substrate and form a strong bond between the stud and the substrate. Phase II will design and build a P-Wave radiation system with waveguide and thermal feedback controller for use to irradiate and bond the stud while holding with a vacuum holding fixture. Thermal analysis and mechanical testing of candidate PTIR adhesive and substrate materials will define process conditions to rapidly cure the adhesive and with bonding strength that equivalent to the benchmark adhesive performance at a processing temperature below the substrate surface degradation limit. The PTIR adhesive formulation, P-Wave unit, holding fixture and PTIR OOA process will be scaled up to demonstrate high speed stud fastener bonding for aircraft manufacture and repair.