Production-Optimized Composite Shafting with Novel Ballistically-Tolerant Laminate Architecture

KaZaK Composites will leverage our currently active development program for new composite LCAC shafts, applying this evolving technology to development of similar composite CH-53K shafts. As CH-53K progresses through development, a novel drive shaft solution is desired that reduces weight and cost, and also improves ballistic durability compared to the legacy shaft. Composite material offers an attractive solution, but in some cases where traditional composite design and manufacturing methods such as braiding and RTM were used, weight savings from composite shafts were disappointing due to the additional material required to meet ballistic tolerance requirements. KaZaK proposes to work with world-class experts in composite materials and shaft design, along with a leading helicopter manufacturer, to demonstrate a novel laminate technology that has been shown to considerably increase strength and fatigue resistance compared to conventional layups. We will show that delamination resistance of our proposed laminate architecture will translate to enhanced ballistic performance, as has already been demonstrated for strength and fatigue. In Phase I KaZaK will develop a composite design optimized for our material approach (using IM7/8552), then produce and test samples demonstrating the efficacy of the new solution for mitigation of damage propagation, resulting in a lighter ballistically tolerant solution.