Technologies for the Rapid Curing of Composite Parts (PVCI08-007-1)

Bismaleimide (BMI) 5250-4 and epoxy 977-3 material systems are used in F-35 aircraft composite components fabricated via autoclave. Alternative out-of-autoclave processes can reduce manufacturing costs by lowering capital and tooling costs and providing faster cure cycles, if properties can be maintained. Feasibility of the Quickstep out-of-autoclave process for 5250-4 and 977-3 material systems has been demonstrated in prior work. In Phase I, the Quickstep process reduced the heating and cooling time by 40 percent compared to an autoclave process for 5250-4. The Phase II program objective will be to demonstrate the Quickstep out-of-autoclave process for manufacturing composite structures from 5250-4 resin on IM7 fibers and 977-3 resin on IM7 fibers, with equivalent properties and reduced fabrication costs compared to autoclave processing. The Phase II scope will include the following for both material systems and two F-35 components: Quickstep process development, fabrication and coupon tests to develop a design database, fabrication and test of sub-scale and full-scale articles, and cost comparisons between Quickstep processing and autoclave processing. A key feature of the program includes active participation of F-35 Industry Partners to provide requirements, support process development, test components, and ensure the opportunity for technology insertion into the F-35 program. BENEFIT: Successful completion of this Phase II program will demonstrate that the Quickstep process can manufacture composite structures faster and at lower cost with equivalent properties than autoclave processes for two material systems and component applications for F-35 aircraft applications. The active participation of F-35 Industry Partners will result in generation of a design database, test article design, and subscale and full-scale tests to qualify the Quickstep process for future insertion into the F-35 production program. In addition, this database and testing will result in future insertion of the Quickstep process into other aerospace systems programs which also use the two material systems to provide lower cost alternatives to current autoclave processes.