Encapsulated Resin for Non-Autoclave Resin Film Infusion Composites Repair

Given the importance of composite repair to new aircraft like the F/A-22 and F-35 this SBIR research will provide significant improvement to the warfighter. The development of a powder resin, and dry fabric/Uni repair process that does not require freezer stored materials (room temperature storage), only typical vacuum bag and heat blanket. In phase 1 at the direction of the Air Force customer, we have focused on repair with BMI resin, 5250-4 from Cytec to be specific. We have developed a form of the base resin that preliminary data shows will not advance when stored at room temperature for one year. The new repair and composite fabrication process termed “PIP” Powder Infusion Process has be developed and void free flat panels fabricated buy multiple laboratories with both glass and carbon reinforcement. Fiber volumes meet F-22 BMI spec requirements as does the void content. Micro photographs have shown clean laminates, resembling prepreg cross-sections. This low cost manufacturing process will be further developed and verified or real F-22 aircraft parts in this phase 2 program. This process can be commercialized beyond just repair, but most importantly the process can be transferred to the warfighter for implementation. This process is also is being developed for epoxy repair resin systems and with new breathable membrane to add fabrication process. Initial work is very positive, with epoxy powder and panel being successfully fabricated. The membrane material being developed and utilized is placed over then entire repair area, and allows air and volatiles to be removed with vacuum while not allowing the liquid resin to pass through. The two technologies being developed, and having been demonstrated, are an advancement in not only composite repair, but also in composite processing in general. This phase 2 program will not only further the development of these technologies but will ready them for transition to the warfighter.