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

Current production methods for the composite galvanic isolation ply on the F-35 requires too much time for fabrication and are excessively expensive. TRI/Austin proposes to develop and test unique rapidly curing ultraviolet matrix resins producing innovative high performance, ambient storable, prepreg compositions for the F-35 program and ancillary future applications such as aircraft composite repair. A systematic development and testing program will result in a unique prepreg composition that cures within five minutes and produces a very high glass transition temperature composite. Experimental design techniques to be utilized will systematically evaluate formulation and processing components resulting in a low cost, rapid curing, well adhered, environmentally benign, and chemically resistant isolation ply. The effectiveness of our technical approach will be demonstrated in the course of laboratory based testing including glass transition temperature, cure time, resistance to typical aerospace fluids, weight, density, and thickness. This systematic approach has been proven to be the most effective method for the development of new materials and processes. Throughout the Phase I and II, TRI/Austin will work in cooperation with a prepreg manufacturer and the awardees of topic N08-137. Immediate benefits of this endeavor for the F-35 program are reduced costs, manhours, and increased production.