Novel Low Cost Thin Ply Composite Shafting for Power Transmission

Air Cushion Vehicles (ACV) utilizes steel shafts to transmit power to the propeller and lifting fans. These shafts are exposed to severe environments including constant salt spray, sand particles, and extreme dynamic loading. The next generation ACV, Joint Maritime Assault Connector (JMAC), will require greater lift capacity, increasing power transmission needs up to 65%. Scaling current baseline steel shaft designs to accommodate increased JMAC requirements would add considerable weight, unacceptably reducing payload. Because they are easily installed and removed, composite shafting provides a low risk path to weight reduction in both current and future ACVs. Composites offer the ability to tailor laminates to specific loads, while providing superior vibration damping. KaZaK proposes to provide the Navy with a composite shaft solution evolved by comparing alternative material and manufacturing processes optimized for the unique ACV operating constraints, resulting a shaft with the lowest possible acquisition and life cycle cost while meeting all performance objectives. Use of novel “Thin-Ply” technology will improve damage tolerance and fatigue life, reduce maintenance cost and improve maintenance schedule, while providing a weight efficient solution. Final designs will be validated through Phase I prototype testing in preparation for full scale development and test in Phase II.