Very Rapid Cure Capable Resin and Optimization for Pre-Preg Process Development of Barrier or Isolation Ply Materials

The current manufacturing processes used for restoring corrosion protection on F-35 aircraft composites panels are time consuming and wasteful. The goal of this Phase II program is to demonstrate and deliver a low-energy-cure, epoxy-fiberglass prepreg that can be used to restore the galvanic barrier on the F-35 fighter aircraft. Ultraviolet (UV) and Light Emitting Diode (LED) cure resin systems represent excellent candidates for alternative, “Green” processing technologies. In this program, a new galvanic barrier ply will be developed and applied to the surface of an existing composite structure and cured rapidly without using pressure or a vacuum bag for consolidation. Critical performance requirements for non-structural, fiberglass barrier ply materials that are cured onto military flight hardware include: low and high temperature resistance, hot-wet exposure resistance, fluid resistance, and good adhesion properties to the base composite substrate. A high level of interaction will be needed between the composite parts fabricator, formulated resin/prepreg material supplier, and the UV/LED lamp system provider for the successful transition of low-energy cure into production. When compared to current methods for galvanic restoration barrier systems, the new material, along with the low-energy processing equipment, will result in significant savings in both fabrication time and cost.