Automated SBCF MRB Spar (ASMS)(1001-175)

Triton Systems Inc., in combination with HEXCEL, Ingersoll, and a helicopter or tiltrotor airframe prime contractor, proposes to develop a novel manufacturing technique combining the formability of stretch broken carbon fiber (SBCF) with automated fiber placement to dramatically reduce costs for high performance main rotor spars. The automated fiber placement promises to virtually eliminate the principal cost of making main rotor spars, and the SBCF characteristics promise to simplify the processing required to achieve high quality spars. During the Phase I Triton will develop a demonstration spar geometry in combination with the airframe prime, and fabricate the molding tooling required for several trials. Ingersoll will perform automated fiber placement on the demonstration mandrels, and ship the laid-up components to Triton. Triton will conduct molding and curing trials to develop the process to a finished quality level commensurate with main rotor spar requirements. During the Option Phase Triton will perform detailed NDE and destructive examination of the trial spar elements fabricated in the Phase I to identify the correlation between ultrasonic characterization and composite quality. Additional automated fiber placement panels will also be fabricated using SBCF in order to provide specimens for mechanical property testing, including tension, compression, and shear.